HYDRONIC RADIANT HEATING SYS TEMS - MacDonald · PDF filehydronic radiant heating sys tems...

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HYDRONIC RADIANT HEATING SYSTEMS INSTALLATION INSTRUCTIONS Revised July 2005

Transcript of HYDRONIC RADIANT HEATING SYS TEMS - MacDonald · PDF filehydronic radiant heating sys tems...

HYDRONIC RADIANT

HEATING SYS TEMS

INS

TAL

LA

TIO

N IN

ST

RU

C T

ION

S

Revised July 2005

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Congratulations on the selection of Vanguard’s Vanex® PEX (cross-linked polyethylene) tubing and components for your Hydronic Radiant Heating System installation. This installation guide is presented to assist installers, designers and code offi cials in the quality installation and inspection of a Vanguard Radiant Heating System. This installation guide relates specifi cally to PEX tubing and components supplied by Vanguard Piping Systems, Inc. and is not applicable to tubing or components from other manufacturers.

To assure the successful and quality installation of a Vanguard Hydronic Radiant Heating System, it is important that those doing the installation read and understand this guide, fully. Since many hydronic heating systems are literally “cast in concrete”, and must endure a very long service life, it is very important that the PEX tubing is not damaged during installation or by further construction activity after installation. PEX tubing is a durable product; however, nails, staples, shovels and other sharp objects or tools can damage it. Damage that compromises the integrity of the tubing can lead to premature failure and is costly to repair. Exercising a reasonable amount of care during the installation process and making other trades aware of the presence of the tubing will help insure that the PEX tubing will perform without incident for decades to come and will probably outlast the structure.

The key to the fl awless performance of any radiant fl oor heating system relies heavily upon proper planning. Each system must be properly designed for the particular structure and the system must be installed in accordance with that design. A radiant fl oor heating system cannot cure a heating problem in a poorly insulated or uninsulated building. Since radiant fl oor systems operate at relatively low temperatures, are limited to the available fl oor area and are diffi cult to modify after installation, the heating system must be designed to provide the required heat-load of the building or supplemental heat must be a part of the design. This guide contains no signifi cant heat-load design information. However, Vanguard’s Hydronic Radiant Heating Design Software is available to assist system designers. Other, industry accepted methods of calculating heat-load design requirements can also be employed. Do not attempt to install a system without a proper heat-load design as it invites poor system performance and can adversely affect the comfort level attainable by the system.

Thank you for choosing the Vanguard System.

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TABLE OF CONTENTS

SYSTEM BASICS ....................................................................................................................................................................4

SYSTEM COMPONENTS ...................................................................................................................................................5

DEFINITIONS .........................................................................................................................................................................7

BEFORE YOU BEGIN ..........................................................................................................................................................8

PEX TUBING LOOPS ....................................................................................................................................................... 10

TYPES OF FLOOR CONSTRUCTION

SLAB ................................................................................................................................................................................. 11

OVER AN EXISTING SLAB .............................................................................................................................................. 17

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR ....................................................................... 18

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR WITH SLEEP ERS (OR NAILERS) ................ 20

INSTALLATION BELOW THE SUB-FLOOR ..................................................................................................................... 21

MANIFOLD LOCATION .................................................................................................................................................... 23

MANIFOLD CONNECTIONS ......................................................................................................................................... 24

SYSTEM PRESSURE TESTING ...................................................................................................................................... 27

SYSTEM FILLING AND AIR ELIMINATION ................................................................................................................ 28

SYSTEM CONTROLS ........................................................................................................................................................ 30

PIPING SCHEMATICS ...................................................................................................................................................... 31

APPENDIXMAKING CRIMPSERT CRIMP CONNECTIONS ..........................................................................................................A

CRIMP TOOL CALIBRATION ............................................................................................................................................B

ADJUSTING “HCM” TOOLS ..............................................................................................................................................C

ADJUSTING “HAR” TOOLS .............................................................................................................................................. D

ADJUSTING “HAR34ST” TOOL ....................................................................................................................................... E

VANEX REPAIR INSTRUCTIONS ...................................................................................................................................... F

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A hydronic radiant fl oor heating system is really quite simple. Heated water is circulated through Vanex PEX tubing installed in or under the fl oor of the building. As the heated water warms the fl oor, it becomes a huge radiant-heat radiator. Since radiant heat energy passes through air readily and radiates in all directions, it warms the human body and objects in the building without relying on the conduction of heat by air as with forced air systems. The warmth that is felt from the sun easily describes the radiant heat of a fl oor heating system. Even though the sun is millions of miles away, the radiant (also referred to as infrared) heat waves pass through those millions of miles of space and are readily absorbed by the skin. Radiant heating systems offer increased comfort levels while generally allowing for lower building air temperatures.

To provide the necessary heat output from a radiant fl oor system, there must be a suffi cient amount of tubing installed in or under the fl oor and the temperature of the heated water must be within a range that will supply the needed output without overheating the fl oor. A fl oor that’s too warm will be as much a detriment to system comfort as one that is too cool. A properly designed system will maintain a comfortable fl oor temperature while supplying the required heat output.

A minimum hydronic radiant fl oor heating system includes: 1. Water heating unit of suffi cient size to meet the heat-load of the building or space to be heated

2. Circulation pump or pumps

3. Manifold or manifolds to distribute the heated water to Vanex PEX tubing loops and return the cooled water from those loops

4. Vanex PEX tubing loops installed in or under the fl oor

5. Vanex PEX supply and return tubing from the hot-water source to the manifold(s).

6. Thermostatic control to turn water circulation on and off as required.

Generally, additional components are also needed to assure safe and effi cient operation of the system and will be covered in detail throughout this manual.

SYSTEM BASICS

SIM PLI FIED RA DI ANT HEATING SYSTEM

SCHE MAT IC

PAN EL LOOPS

MAN I FOLDS

HEAT SOURCE

A RADIANT FLOOR HEATING SYSTEM USES THE HEATED FLOOR PANEL TO RADIATE HEAT INTO THE HOME OR BUILDING

CIR CU LA TOR

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VANEX PEX TUBING

The key to the Vanguard Radiant Heating System is Vanex PEX tubing. The fl exibility and durability of Vanex PEX offers ease of installation and extremely long service lifetime expectancy when properly installed and operated.

Vanex PEX is also available with an oxygen barrier layer. Oxygen barrier PEX is made available since it has been demonstrated that hydronic heating systems that contain ferrous iron components (steel and cast iron) may be adversely affected by the presence of too much oxygen in the water. Vanex Barrier PEX, having a thin layer of oxygen permeation resistant material permanently applied to the exterior of the tubing, limits the amount of oxygen that can enter the system by permeation through the wall of PEX tubing, substantially reducing the overall aggressiveness of the water towards ferrous iron components. For a more detailed explanation of oxygen ingress into radiant heating systems and its affects, see the Plastics Pipe Institute technical paper TR-4. (PPI phone 888-314-6774 or go to www.plasticpipe.org.)

All Vanex PEX and Barrier PEX is manufactured, tested and third-party listed to meet or exceed the requirements of ASTM (American Standards for Testing and Materials) F 876 and F 877, and CSA (Canadian Standards Association) B137.5. Additionally, both Vanex PEX and Barrier PEX are certifi ed for potable water use and Barrier PEX meets the requirements of German DIN Standard 4726 for oxygen permeation resistance.

SYSTEM COMPONENTS

VANEX HYDRONIC HEATING MANIFOLDS

Vanguard offers three separate lines of supply/return manifolds for hydronic heating systems. System size, control features and economics represent the primary differences between the separate offerings. See the Vanguard Piping Systems Product Catalog for a complete listing of the different manifolds and features.

The size of the system and the desired amount of control for separate zones and/or individual loops will govern the type of manifold and available manifold control options. Very small systems having only one to a few loops may not require a manifold.

Copper Manifolds

VANGUARD VANEX® Barrier PEX 1/2” CTS-OD OXYGEN BARRIER TUBING 100 PSI@180 F [ NSF-pw ASTM F-876/F-877] CAN B137.5 L23707 ICBO ES ER-5287 PEX SDR-9 .070 2/28/02 CB 298

MANUFACTURER TUBE SIZE

TRADE NAME

TEMPERATURE & PRESSURE RATINGS

POTABLE WATERCERTIFICATION

ASTMSPECIFICATIONS TUBING CLASS

DATE CODETUBING TYPE ADDITIONAL THIRD PARTY LISTINGS

INCREMENTAL FOOTAGE

Simplex Man i foldsComap Manifolds

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SYSTEM COMPONENTS

VANEX PEX AND COMPAX-L® PEX-ALUMINUM-PEX (PAX) TUBING FOR SUPPLY AND RETURN PIPING

Larger size Vanex PEX and COMPAX-L PAX tubing (3/4" and 1") is used for the supply and return piping from the water-heating unit to and from the manifolds. For maximum control of oxygen ingress into the system, Vanex tubing is also available as Barrier PEX with an oxygen barrier or the natural properties of the aluminum layer in PAX make COMPAX-L PAX a good choice as well. However, with relatively short supply/return piping runs, the advantage of oxygen barrier tubing for supply/return piping runs is limited. It should be noted however, that some boiler manufacturers, in order to meet warranty requirements, require that all of the tubing in a system be oxygen barrier. Consult with the water heating unit manufacturer for their recommendation.

CRIMPSERT® AND FAILSAFE™ PLUS FITTING SYSTEMS

The Vanguard CRIMPSERT and Failsafe PLUS fi tting systems are used to make transition connections at the water-heating unit and at the manifolds. Vanguard offers an extensive line of fi ttings to make transition connections to all types of water heating units as well as directional changes when required. Consult the Vanguard Piping Systems Product Catalog for a complete listing of available fi ttings, crimp rings and crimp tools.

SYSTEM CONTROLS

Vanguard offers an extensive line of radiant heating system controls. Every radiant fl oor heating system requires some form of control for comfortable and effi cient operation. More complex systems, requiring multiple water temperatures and/or remote on/off control of manifolds or individual loops, will require additional control elements to insure that all heated areas, regardless of heat load demand differences, are properly heated.

BOILERS, PUMPS AND OTHER SYSTEM COMPONENTS

Vanguard does not supply boilers, circulation pumps and other system components (such as expansion tanks and air eliminators). These components are commonly available at wholesalers that supply the hydronic heating market. It is important in selecting components to choose those that are made specifi cally for hydronic heating systems and are of the correct size for the particular system.

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DEFINITIONS

These are terms used throughout this manual that are specifi c to hydronic radiant fl oor heating systems.

Circulator - A pump designed to circulate fl uid through a hydronic heating system. These pumps are generally fractional horsepower and low pressure but large-scale systems may require pumps of considerable size and output.

Downward Loss - The amount of heat energy transmitted downward from a radiant fl oor that is not available to heat the living space.

Edge Insulation - Insulation covering the thickness of the slab edges that are exposed or nearest the outside wall and extending into the ground and preferably to at least the prevailing frost line.

EVOH - ethylene vinyl alcohol - This barrier is used in the outer layer of Vanex barrier PEX to minimize the oxygen transfer into a heating system, reducing the corrosion in boilers and other accessory items.

Expansion Tank - A tank having a fl exible, internal bladder that can be charged with compressed air to compensate for volumetric changes of the fl uid in a radiant heating system due to expansion and contraction caused by temperature fl uctuations of the water.

Head Loss - The pressure, expressed as feet of head, lost to friction as the result of fl owing water (or water/antifreeze mix) through system components. The total head loss for a zone is additive of the losses through each component in the fl ow stream based on the amount of fl ow through each component. Multiple loops on a common manifold are not additive. Only the loss through the longest loop is used.

Injection Mixing - A method of providing temperature-controlled supply water by injecting high-temperature water from the water-heating unit into the cooled, return water from the heating zones.

Loop - A single, continuous loop of tubing in a radiant panel.

Oxygen Permeation - The transfer of oxygen into a closed loop heating system

PAX - PEX-Aluminum-PEX (COMPAX-L) SDR9 tubing is a multilayer tubing consisting of a layer of aluminum sandwiched between two layers of PEX and is intended for hot and cold potable water distribution systems and hydronic radiant heating systems. The aluminum acts as a barrier for oxygen transfer into a heating system, reducing the corrosion in boilers and other accessory items.

PEX - Cross-linked Polyethylene (VANEX) SDR9 tubing intended for hot and cold potable water distribution systems and hydronic radiant heating systems.

Perimeter Insulation - Insulation placed under a slab around its perimeter from the edge of the slab 4 feet in towards its center.

Radiant Floor Panel - A heated area of fl oor used as a radiant heat source.

Thermostatic Mixing Valve (TMV)- A valve that mixes high-temperature water from the water heating unit with cooled, return water from the heating zones to provide a set supply water temperature. A TMV can be manually set or automatically controlled.

Zone - a loop or group of loops controlled by a single thermostat.

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BEFORE STARTING INSTALLATION OF A VANGUARD HYDRONIC RADIANT HEATING SYSTEM, READ, UNDERSTAND AND FOLLOW THESE CAUTIONS:

◆ Vanex PEX or Barrier PEX must not be exposed to direct sunlight for long periods of time. If the tubing is to be stored outdoors, it must be covered to protect it from direct sunlight. For cast-in-slab systems where the tubing will not be protected from direct sunlight during installation, PEX or Barrier PEX tubing must be covered with concrete shortly after laying the loops. The tubing must be covered within 2 weeks or it must otherwise be protected from sunlight exposure. Tubing tails left out of the slab for connection to manifolds must also be protected from sunlight exposure. Too much exposure to direct sunlight will cause tubing embrittlement, loss of long-term stabilization and will lead to premature failure.

◆ Pressure test the system before pouring the concrete or other topping material. The PEX tubing loops must be pressure tested before being permanently cast into the fl oor material. Also, leave a lower pressure on the loops while pouring to expose any leaks that might happen during the pour. (See page 28 for further information on system testing.)

◆ DO NOT use tubing that is damaged. DO NOT connect shorter lengths of tubing together to make longer loops. Unless damaged during topping pour, there should be no joints in the fl oor loops. It must always be the policy to use only continuous lengths of PEX tubing for fl oor loops. (See appendix F for repair of loops damaged during the pour.)

◆ Inform the other trades working on the same structure of the fl oor loops. Common damage to PEX tubing loops is from staples, nails, screws, or other sharp fasteners. Informing the other trades of the presence of the loops may help prevent damage.

◆ Follow the guidelines for attaching the PEX tubing. Fasteners that are too tight or that have sharp edges can cause damage to the tubing over time and can lead to premature failure.

BEFORE YOU BEGIN

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◆ DO NOT fi ll the system with water if there is any possibility that freezing conditions might occur. If the system is fi lled with plain water (no antifreeze), and freezing temperatures are encountered, the tubing will likely burst at expansion joints or at naturally occurring voids in the concrete. While PEX tubing out of the slab is not prone to freeze damage, tubing encased in concrete will likely burst from the expansion of the water as it turns to ice. The resulting pressure increase inside the tubing will seek a point of least resistance and burst the tubing at that point. Substantial slab damage can also result.

32°F(0°C)

SYSTEM MUST BE PROTECTED IF

FREEZ ING TEMPERATURES ARE POSSIBLE

ADDITIONAL CONSIDERATIONS BEFORE STARTING

◆ Do you have details for loop spacing and lengths for each room or zone? For the system to operate properly, an accurate room-by-room heat-loss must be done to calculate loop spacing, loop lengths and water temperature(s). Installing a system without fi rst performing a heat-loss evaluation of the structure is an invitation to poor and/or ineffi cient system operation.

◆ All fl oor coverings must be considered for the system to operate properly. It must be understood that certain changes in the fl oor covering can adversely affect system function and effi ciency. Carpet pad type and thickness, carpet type and pile height, the thickness of coverings such as stone or marble can all affect system output and may require closer loop spacing or higher delivered water temperature. The system designer must be made aware of any changes to fl oor coverings before placing PEX loop tubing.

◆ Laying of PEX tubing loops and pouring of regular or thin slab should be coordinated with the other trades working in the same structure. Once you start laying out potentially thousands of feet of PEX tubing in a structure it is important that other trades are not walking on and working over the tubes. This is an invitation for damage and may result in leaks if the damage is not found and repaired prior to covering the tubing. The placement and covering of radiant loops must be coordinated with other trades to minimize, to the greatest extent possible, damage to the tubing prior to and after the slab pour.

◆ When considering thin-slab, it is important to locate an applicator. Since thin-slab is a relatively new and specialized application, there are generally only a few, if any, applicators in various regions of the country. Therefore, we recommend you locate an applicator prior to placing PEX loop tubing.

◆ Since radiant systems use a substantial amount of Vanex PEX tubing, it is important to arrange with the wholesaler to have the required amount of tubing on hand when you need it. Wholesalers that don’t generally serve the hydronic heating industry may not have the type, size and quantity of Vanex PEX on hand when you’re ready to starting laying out loops. It is important to plan the number and size of tubing coils as well as manifolds, fi ttings, ties, and tools and to convey those needs to the wholesaler in advance so that the materials will be available. Vanguard’s Hydronic Heating Software will prepare a list of materials complete with part numbers.

BEFORE YOU BEGIN

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LAYOUT BASICS

Each radiant fl oor panel will contain one or more loops of Vanex PEX tubing through which the heated water is circulated. To ensure proper heat output from the panel the loops must be laid out in a specifi c pattern and attached at specifi c intervals. Also, the length of individual loops must not be too long. The system design will specify the number, length and spacing of loops. Loops that are too long will experience higher than necessary head-loss and temperature drop and will lead to poor system performance.

For panels with more than one loop, the length of individual loops within the panel should be within 10% to prevent inconsistent heat output. Even though individual loops connected to the same manifold can be adjusted at the manifold with built-in balancing valves, it is better to have consistent loop lengths as balancing individual loops can be a tedious trial and error task unless individual fl ow meters are used on each loop increasing system cost.

Maximum loop lengths for the different sizes of PEX tubing are shown in the chart on the right, however, the panel design should dictate the actual lengths used for any particular radiant panel.

Typical loop spacing is 4" to 15" and is dependent on the location of the loops within the room and the required heat output of the radiant panel. Loops spaced too far apart will lead to cold spots between the loops and can also require higher supply water temperatures and will lower panel output.

PEX TUBING LOOPS

3/8" 8" 1/2" 10"

5/8" 12" 3/4" 14"

1" 18"

Dimension X Tubing Size With the Coil

X

X

Each size of Vanex PEX used in radiant fl oor loops has a minimum bend radius dimension. When the loops are spaced closer together than the minimum bend radius X 2, then 180° turns in the tubing need to be swept out to the minimum dimension as shown below.

LOOPS SPACED TOO FAR APART LEAD TO HOT AND COLD SPOTS AND POOR PERFORMANCE. THE SPACING DICTATED BY THE SYSTEM DESIGN MUST BE FOLLOWED.

RIGHT WRONG

85° 83° 85° 105° 80° 105°

120° 120° 140° 140°

FOR LOOP SPACING LESS THAN “X”, SWEEP THE TUBING AS SHOWN

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WARNING! Excessive sunlight exposure will damage PEX tubing! If the loop ends protruding from the slab will not be shielded from direct sunlight within 2 weeks

of tubing installation they must be protected from sunlight exposure. Wrap the tubing with black plastic or otherwise cover it to completely shield the tubing from sunlight. Failure to do this will result in premature tubing failure.

To minimize waste, select coil lengths based on the required loop lengths. Vanguard makes Vanex PEX tubing available in numerous coil lengths and, while there may not be a coil length that matches each required loop length, a longer coil can be cut into several loops as needed. A little planning before ordering loop tubing can result in substantially reduced tubing waste.

The Vanguard Radiant Heating Design Software automatically selects the best coil lengths for each system layout.

Always mark both ends of each tubing loop during placement. The marking must indicate which end is the send and which is return and it should also be marked with some form of loop number or other identifi er when numerous loops are connected to the same manifold. A permanent marker (such as Sharpie® or Marks-a-lot®) is usually suffi cient or a fl ag of tape can be attached to the portion that will be trimmed off when connected to the manifold. This is an important step and is critical if the manifolds will not be placed immediately.

Alternately, the loops can be connected to the manifold immediately but the loops must still be identifi ed as to manifold position for balancing and other adjustments.

Individual Vanex PEX tubing loops must always be run in a continuous length from the manifold, through the layout and back to the manifold. This is especially important for systems where the tubing will be cast into concrete or other material. DO NOT connect shorter lengths of tubing together to make up needed loop lengths. Some connections are allowed in systems where the tubing is not “cast-in”, however, fi ttings in the loops must be kept to a minimum.

If the manifolds have not been placed prior to installation of the loops, the ends of the loops can be connected together temporarily to facilitate pressure testing. The fi gure to the right shows one method of connection the loops so that they can be pressure tested together. When doing this, ensure that there is suffi cient tubing to make manifold connections after the temporary fi ttings are cut out.

PEX TUBING LOOPS

ALL PEX TUBING LOOPS MUST BE IDENTIFIED FOR CONNECTION, PURGING

AND BALANCING

PEX TUBING LOOPS MUST BE PRESSURE TESTED BEFORE POURING SLAB. A LOWER

PRESSURE SHOULD BE MAINTAINED ON THE SYSTEM DURING THE POUR.

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PEX TUBING LOOPS

Each radiant panel requires a layout that is specifi c to the space being heated. The illustrations below show the most common loop layouts but these may need to be modifi ed for some rooms.

The rule is that the supply side of each loop (with the hottest water) is installed towards the exterior wall or walls and the cooler part of the loop (as it is returning to the manifold), is installed towards the room’s center or interior walls. The design may also require closer spacing near the outside walls, commonly called perimeter banding, to account for higher heat loss.

For rooms with no exterior wall, it is recommended to use the counter-fl ow spiral pattern to provide the most even heating.

At high radiant panel heat-loads, loop lengths, loop spacing and layout become more critical. Please remember that modifying a layout once the fl oor covering has been placed is nearly impossible without completely destroying the fl oor and starting over. It is better to plan ahead to prevent potential problems.

SINGLE SERPENTINEOutside Wall

DOUBLE SERPENTINEOutside Wall

Outside W

allO

utside WallO

utsi

de W

all

TRIPLE SERPENTINEOutside Wall

SINGLE SERPENTINE WITH PE RIM E TER BANDING

Outside Wall

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SLAB

Slab construction is well suited to radiant fl oor heating since the warmed concrete becomes a huge thermal mass. For most slab applications, the tubing is tied to the re-mesh or re-bar reinforcement with zip-ties (Vanguard part #HRCT) or re-bar twist ties. When using re-bar twist ties they must not be twisted too tight possibly damaging the PEX tubing. Once the concrete is poured over the tubing, the ties no longer serve an anchoring function so they need not be installed overly tight.

Tie the tubing to the re-bar or re-mesh every 3-4 feet along straight runs. At 90° turns, tie the tubing within 12" on each side of the turn. For turns greater than 90°, tie the tubing within 12" on each side of the turn and in the middle of the arc to prevent the tubing from moving or fl oating to the top during the concrete pour. (See fi gure at left.)

Keep the PEX tubing at least 6" away from slab penetrations, block-outs or other similar structural embedments. Unless local building code does not allow it, a vapor barrier (such as 6 mil polyethylene sheeting or equivalent) should be installed under the entire slab.

Install only continuous loops of tubing into the slab. Starting at the manifold location and leaving suffi cient tubing to make the manifold connections, run each loop continuously through the loop layout and back to the manifold location. DO NOT connect several shorter lengths of tubing together the make a complete loop. Vanguard supplies Vanex PEX in numerous coil lengths to minimize waste. To provide for a cost-effective installation, order coil lengths that are either close to the required loop lengths or that can be cut into lengths that will minimize the length of “tails” to be cut off.

TYPES OF FLOOR CONSTRUCTION

Run continuous lengths of Vanex pex through the loop layout and back to the manifold location. Use HRSL3 or HRSL4 plastic elbows or HRCSL3 or HRCSL4 corrugated sleeving where the tubing enters

the slab. Elbows or sleeving can be tied to re-bar sup ports as shown. Cut re-bar off fl ush with concrete when cured.

Elbows or sleeving may be tied on alternate sides of support to provide better line-up with mani-folds.

LOOP TUBES ARE ATTACHED TO RE-MESH (SEE TEXT)

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Ideally, the PEX tubing loops should be placed about 2 inches below the top surface of the slab. This is usually accomplished by installing risers that hold the re-bar or re-mesh at a constant height, or during the concrete pour, by hand pulling the reinforcement (with PEX tubing attached) to the desired level.

NOTE: All fi ll material below a radiant slab must be free of sharp objects that can damage the Vanex PEX tubing. If gravel is specifi ed for under-slab fi ll, it must not have sharp edges. Smooth pea gravel is recommended.

TYPES OF FLOOR CONSTRUCTION

INSULATIONExposed slab edges must be insulated for effi cient system operation. The most common edge insulation is 1 to 2 inch in thick, closed-cell Styrofoam extending down to at least the prevailing frost line. The system design should specify the type and thickness of edge insulation.

If edge insulation to the prevailing frost line is impossible or impractical, at the very least, edge insulation should fully cover the exposed slab edge and extend into the ground at least a few inches. Remember if the design specifi es edge insulation to the frost line and that recommendation is not followed, the slab will experience higher edge heat loss, may not perform properly and system effi ciency will suffer. In extreme cases, failure to install edge insulation where the system design calls for it could result in enough additional heat loss to overrun the boiler output.

When attaching insulation to the slab forms prior to pouring, adjust the form position outward the thickness of the insulation so that the outer wall does not sit partially on the insulation.

CAUTION! DO NOT drill into or drive fasteners into the slab as you can puncture the PEX tubing causing a leak. Make the other construction trades aware of the presence of the

tubing to minimize the risk of this type of damage as it is diffi cult and costly to repair. If the slab must be penetrated, the tubing loops must be accurately located to prevent damage.

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TYPES OF FLOOR CONSTRUCTION

The top of exposed edge insulation should be angled to provide water run-off and should be covered with fl ashing or other metal trim to prevent degradation of the foam.

TO FROST LINE

TO FROST LINE

4 FT. OR PER DESIGN

ADJUST FOR IN SU LA TION THICKNESS

When setting insulation prior to pouring a mono-pour slab/foundation, adjust the width of the trench and the placement of the forms to accommodate the additional thickness of the insulation so that the outer wall does not sit on the insulation.

Perimeter insulation is also recommended to promote effi cient operation and to minimize heat loss. Perimeter insulation should extend a minimum of 4 feet inward from the outside slab edges and be installed around the entire outside perimeter of the slab.

Edge and perimeter insulation will minimize the majority of heat loss; however, certain conditions may require full under-slab insulation to further minimize downward heat loss. Those conditions include high water table, high slab heat-load, and high R-value fl oor coverings. If there is a question as to the need for full under-slab insulation, consult the system design and/or the system engineer.

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TYPES OF FLOOR CONSTRUCTION

HRCSL3 OR HRCSL4Plastic Turnout: HRSL3 or HRSL4Plastic Snap-on Sleeve: HRCSL3 or HRCSL4

When using full underslab insulation and securing the PEX loop tubing directly to the foam insulation, the R-value of the cover-ing over the tubing increases and system response and required water temperature will be affected. An increase in the thickness of covering over loop tubing results in higher required water tem per a ture and can cause sluggish system response to chang- ing heat loads. The system control type or control parameters may require adjustment to accommodate the delay in system response time.

If fastening the PEX tubing directly to the foam insulation, see Over an Existing Slab for fastening instructions.

In some rare instances, the PEX tubing must be placed in the sand backfi ll below the slab. Use caution with this method as system response time and required water temperature is signifi cantly affected. Also, water temperature must not exceed 140° F to prevent crystallization of the sand which leads to very poor heat transfer. Do not place the tubing in the sand below the slab unless the system design specifi es it directly.

PEX tubing must be sleeved at all expansion joints and every point where it enters, exits or penetrates the slab. For expansion joints that are to be cut, the tubing must be dipped below the slab to prevent damage.

COVERING THICKNESS > 2” OVER LOOP TUBING RESULTS IN HIGHER WATER TEM PER A TURES AND

CAN CAUSE SLUG GISH RESPONSE

FOR COVER > 2”

DO NOT PLACE PEX TUBING LOOPS IN THE SAND BED BELOW A SLAB UNLESS THE DE-

SIGN SPECIFIES IT

SLEEVE PEX TUBING AT ALL EXPANSION JOINTS WITH HRCSL3 OR HRCSL4

SLEEVE EVERY POINT WHERE THE PEX TUBING ENTERS OR EXITS CON- CRETE. USE HRSL3 OR

HRSL4 ELBOWS OR HRCSL3 OR HRCSL4 SLEEVING

FOR CUT EXPANSION JOINTS, DIP THE TUBING BELOW THE SLAB TO A SAFE DISTANCE AT THE CUT LINES

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NOTE: Omis sion of in su la tion be tween the new slab and the old slab will sub- stan tial ly in crease the ther mal mass, mak ing re sponse times very slug gish.

Pour a min i mum of 3/4” slab thick ness over the loop tubing.

3/4"

TYPES OF FLOOR CONSTRUCTION

The remaining instructions for a slab over an existing slab follow those for a Slab installation on pages 13 through 16. However since insulation between the new and existing slabs is recommended, and the new slab will likely be only about 2” thick, then the tubing can be fastened directly to insulation laid over the entire surface of the existing slab. Attach the tubing to the insulation with foam staples (Vanguard Part No. STAP1 or STAP2), screw-in tubing clips (Vanguard Part No. CLC3 for 1/2” only) or install CLMR3 or CLMR4 Snap-Trak to the insulation and snap the tubing into the supplied slots. The distance between tubing fasteners shall be the same as shown in the Slab installation section.

WHEN USING STAP1 OR STAP2 STAPLES, DOUBLE STAPLE ON BOTH SIDES

OF EACH TURN AND SINGLE STAPLE IN THE MIDDLE OF THE ARC FOR TURNS GREATER

THAN 90°.

OVER AN EXISTING SLAB

For existing or new applications, a new slab can be installed over an existing one to provide for a radiant heating panel. Insulation should be installed between the new and existing slabs (1” minimum recommended) that helps drive the heat upwards and insures that the system reacts properly to changes in the temperature of the living space. This is very important when coverings such as carpet and pad are used over the new slab. If insulation between the slabs is omitted, the thermal mass increases substantially and the system will be sluggish in responding to changes in room temperture.

For the most part, a slab over slab is installed like a Slab system except that the new slab, since itis generally only about 2 inches thick, may not contain steel reinforcement and the tubing loops may be attached directly to the insulation with the methods described in this section. Please note, if the thickness of the new slab over the tubing will be substantially more than 2”, the system design must be consulted. Too much slab thickness over the tubing will cause sluggish response to changes in room temperature.

When installing the tubing in a poured slab over an existing slab, the tubing can be anchored by:

1. Attaching to re-mesh or re-bar laid over the existing slab as described in the Slab installation section.

2. Attaching directly to the insulation with staples (Vanguard Part No. STAP1 and STAP2) or screw-in clips

(Vanguard Part No. CLC3)..

3. Attaching Snap-Trak (Vanguard Part No. CLMR3 or CLMR4) to the insulation with fasteners or adhesive and snapping the Vanex PEX tubing into the provided slots as shown in the illustration to the right.

(See text)

18

Do not drill or drive fasteners into the poured fl oor as you can puncture the tubing

causing a leak. Inform the other construction trades of the presence of the tubing to minimize the risk of damage during further construction.

3/4"There must be at least 3/4" of poured underlayment/thin slab over the top of the tubing.

TYPES OF FLOOR CONSTRUCTION

When installing a poured fl oor underlayment/thin slab over a suspended wood fl oor, attach the Vanex PEX tubing directly to the wood sub-fl oor with staples or clamps every 2 to 3 feet along straight runs. At turns, attach within 12" on both sides of each turn and also in the middle of the arc for turns greater than 90°. When using staples, do not use staples with sharp edges and do not drive them to a depth that deforms or crushes the PEX tubing. Clamps must also be free of sharp edges that could cut or damage the tubing.

Install only continuous loops of tubing into the poured underlayment/thin slab. Starting at the manifold location and leaving suffi cient tubing to make the manifold connections run each loop continuously through the loop layout and back to the manifold location. DO NOT connect several shorter lengths of tubing together the make a complete loop. Vanguard supplies Vanex PEX in numerous coil lengths to minimize waste. To provide for a cost-effective installation, order coil lengths that are either close to the required loop lengths or that can be cut into lengths that will minimize the length of “tails” to be cut off.

COR RECT IN COR RECTSTAPLES MUST NOT BE DRIVEN TOO

DEEP AND DEFORM THE TUBE. THERE WILL BE A SLIGHT AMOUNT OF PLAY

BETWEEN THE TUBING AND THE STAPLE WHEN PROPERLY DRIVEN.

Thin Slab

Subfl oor

In su la tion

WHEN USING STAP1 OR STAP2 STAPLES, DOUBLE STAPLE ON BOTH SIDES

OF EACH TURN AND SINGLE STAPLE IN THE MIDDLE OF THE ARC FOR TURNS GREATER

THAN 90°.

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR

19

If interior walls are to be set on the poured underlayment/thin slab, keep the PEX tubing at least 3" away from wall locations. Before laying out the tubing loops, mark out the wall locations on the sub-fl oor to insure accurate placement.

The joist spaces below the heated fl oor must be insulated. If the fl oor is over an unheated space, install a minimum R19 insulation. Foil faced insulation is preferred and the foil face is installed towards the heated side. If the space below is heated, install a minimum R11 insulation. As a general rule, the R-value of insulation below a suspended panel should be at least 4 times the R-value of the material covering the tubing (including the poured material and any fl oor coverings).

TYPES OF FLOOR CONSTRUCTION

NOTE! Install plastic elbows (HRSL3 or HRSL4) or sleeving (HRCSL3 or HRCSL4) to direct the tubing loops up to the manifolds. A 1x4 in stalled between studs provides a surface to clamp to. Staple or clamp tubing to sub-fl oor every 3-4 feet along straight runs and within 12 inches on each side of turns and in the middle of the arc for turns greater than 90°.

3”

MARK WALL LOCATIONS ON THE SUBFLOOR AND KEEP PEX TUBING LOOPS AT LEAST 3 INCHES AWAY

FROM THEM.

NOTE! Insulating below a radiant fl oor panel is important even when the space below it is heated. The insulation “drives” the heat upwards since radiant heat emits from both sides of the heated panel. If no insulation is installed, the panel will emit radiant energy equally in both directions and the space above the fl oor will not be heated properly. Foil faced insulation or a separate radiant barrier can signifi cantly improve insulation performance since it refl ects infrared waves directly.

FOIL FACING OR RADIANT BARRIER

INSULATION - R11 TO R19 (SEE TEXT)

20

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR WITH SLEEPERS (OR NAILERS)

TYPES OF FLOOR CONSTRUCTION

Leave suffi cient space between sleeper ends to make turns and supply/return runs to and from man i folds

Insulation of a thin-slab with sleepers fl oor is identical to thin/slab without sleepers. (See page 19 for details.)

FOIL FACING OR RADIANT BARRIER

INSULATION - R11 TO R19 (SEE TEXT)

Thin Slab

Sleeper

In su la tion

Subfl oor

When the fi nished fl oor over the heated panel requires nailing (such as hardwood), 2x2 sleepers are installed between the tubing runs and the underlayment/thin slab is poured over the tubing and screed level with the sleepers.

Other than the attachment of sleepers to the sub-fl oor, installation of this type of panel is identical to the Poured Underlayment/Thin Slab Over Suspended Floor.

21

The illustration above shows the most common method of pulling the PEX tubing through holes drilled through the joists and into the joist spaces. After suffi cient tubing has been pulled into all of the joist spaces, attach the tubing by nailing, stapling or screwing the heat emission plates to the underside of the sub-fl oor with shingle nails, staples or screws. Fasten each plate every 4-6 inches along each side of tubing-groove placing fasteners about 1/2” away from each side of the groove as shown in the fi gure at right.

INSTALLATION BELOW THE SUB-FLOOR

TYPES OF FLOOR CONSTRUCTION

Heat Emission Plates

In su la tion

Subfl oor

Vanex PEX tubing is installed under the sub-fl oor using the Vanguard Part No. HRTP3 Heat Emission Plate. Normally, two tubes will be installed into each joist space but check the system design, as some will only require one. The heat emission plates are used to fasten the tubing against the underside of the sub-fl oor and help distribute the heat more evenly.

22

CAUTION! The fasteners must not be too long as they can protrude through the fi nished fl oor. Be aware of the thickness

of the fl ooring and use the appropriate length fasteners.

Install insulation in the joist cavity below the PEX loops leaving a 1 to 2 inch air gap. A foil faced insulation or a separate radi-ant barrier will improve heat fl ow towards the heated space. For fl oors over unheated spaces, install as much in su la tion as prac ti cal but at least R19. Insulate even if the fl oor is over a heated space with R11 to drive the heat upwards.

TYPES OF FLOOR CONSTRUCTION

Holes through joists for tubing bundles must be suffi ciently sized to allow free movement of the tubing. Single tubes or a bundle must NOT fi t tight in holes through joists or noise may occur during expansion and contraction. Holes must not be so large as to compromise the strength of the joist. Check the building code for allowable hole size. It may be necessary to have more, smaller bundles if required hole size exceeds that allowable. Bundle PEX tubes with only nylon cable ties (zip-ties) such as Vanguard Part No. HB14120. DO NOT bundle tightly. Leave the ties slightly loose to allow the tubes to freely expand and contract. DO NOT use tape to bundle.

1-2”

WRONG RIGHT

AIR GAP

FOIL FACE OR RADIANT BARRIER

R11 MINIMUM OVER HEATED SPACE, R19 MINIMUM OVER

UN HEAT ED SPACE

BUNDLE TUBES WITH ZIP-TIES. DO NOT USE TAPE.

23

Since most whole-house radiant heating systems will require numerous tubing loops and at least one radiant manifold, consideration must be given to the location of the manifold or manifolds in relation to the water heating unit and the heating zones served by each. Some systems also require more than one delivered water temperature and may also require remote on/off control of one or more manifolds or even of individual loops.

For systems requiring more than one delivered water temperature, separate manifolds are required for each water temperature. Of course, with very large residential or commercial systems there may be multiple manifolds for each delivered water temperature.

It is not required to install manifolds in a dedicated space such as the mechanical room. While that arrangement may work for some systems, there are many times when the manifold(s) will be installed throughout the structure in accessible but unobtrusive locations such as in a closet, a wall or under a cabinet. Manifolds can be covered with a simple duct grate or more elaborate cover. They must, however, remain accessible and must not be permanently concealed behind Sheetrock or plaster.

MANIFOLD LOCATION

NOTE: Mounting the manifolds near the area they are intended to serve will more accurately heat those areas and be a more effi cient use of the tubing. It also reduces the risk of un in ten tion al ly over heating a supply and return tubing pathway from the manifold to the area it is serving, such as a hallway leading to several remote rooms.

RADIANT MANIFOLDS CAN BE MOUNTED WITHIN A 2X6 WALL CAV-

ITY BEHIND A DOOR OR RE MOV -ABLE COVER.

SOME SYSTEMS REQUIRE THAT RADIANT MANIFOLDS BE INSTALLED IN SEPARATE LOCATIONS. 3/4” OR 1” VANEX PEX IS USED AS SUPPLY/RETURN TUBING TO THE REMOTE MANIFOLD(S).

RADIANT MANIFOLD LOCATIONS

24

RADIANT MANIFOLDS

Vanguard offers several lines of send/return manifolds specifi cally for hydronic radiant heating systems. While each manifold type serves the same essential function, there are distinctions that make them more or less applicable to some applications.

MANIFOLD CONNECTIONS

COMAP MANIFOLDS

The Comap line of radiant manifolds is a modular system that consists of an end connection kit, a balancing module, a actuator module and the loop fi tting. The manifold is fi eld assembled by connecting the required number of balancing and actuator modules with an end connection kit. Any manifold from 2 to 12 ports can be constructed from the modular components. Changes to the number of loops can be done quickly simply by inserting or removing balancing/actuator modules.

The end connection kit features manifold isolation valves, air vents and thermometers and includes mounting brackets to attach the manifolds. The main inlet/outlet connection to manifold supply tubing is 1" female NPT.

The balancing and actuator modules look identical but are distinguished by the color of the adjustment knob. The balancing (or supply) module (HRCMSM) has a black adjustment knob and the actuator module (HRCMRM) has an orange adjustment knob. Also available is a return module with a built-in fl ow meter (HRCMFLM) so that adjustments in the fl ow of individual loops can be visually monitored.

Loop connections are available in Euro-compression (1/2" and 5/8") that require only a wrench to connect and CRIMPSERT (1/2" and 3/4") that use the standard PEX black-copper crimp rings and crimping tools.

For systems requiring on/off control of individual loops, the HRLA24V loop actuator mounts directly on the actuator module and also provides an end switch to activate other system control functions. For each loop using a loop actuator, balancing is done through the built-in valve on the supply module.

Air Vent

Wireform Module Connector

Termination Module with Fill Purge Con nec tion

Manifold Con- nec tion with Tem per a ture

Gauge

Manifold Isola-tion Valve with 1” FPT Connec-

tion

Send and Return Module (Black Knob - Balancing)(Orange Knob - Actuator)

HRLA24V Mounted on Return Module for Individual Loop Actuation

Wireform Module Connector

Wireform Module Connector

Euro Style Compression FittingCrimpsert Loop Fitting

(requires crimp ring)

Return Module with Flow Meter

25

MANIFOLD CONNECTIONS

SIMPLEX MANIFOLDS

The Simplex line of radiant manifolds is a modular system that consists of an end connection kit, a balancing module, a actuator module and the loop fi tting. The manifold is fi eld assembled by connecting the required number of balancing and actuator modules with an end connection kit. Any manifold from 2 to 12 ports can be constructed from the modular components. Changes to the number of loops can be done quickly simply by inserting or removing balancing/actuator modules.

The end connection kit features a 1" female NPT for manifold balancing connections, port to install the optional air vent (HRSMAV), fi ll/drain port and includes mounting brackets to attach the manifolds.

The balancing and actuator modules look similar but are distinguished by the fact that the balancing module (HRSMSM) has a brass cover over the isolation valve and the actuator module (HRSMRM) has a black plastic adjustment knob. Also available is a return module with a built-in fl ow meter (HRSMFLM) so that adjustments in the fl ow of individual loops can be visually monitored.

Loop connections are available in Euro-compression (1/2" and 5/8") that require only a wrench to connect and Crimpsert (1/2" and 3/4") that use the standard PEX black-copper crimp rings and crimping tools.

For systems requiring on/off control of individual loops, the HRLA24V loop actuator mounts directly on the actuator module and also provides an end switch to activate other system control functions. For each loop using an actuator, balancing is done through the built-in valve on the balancing module for that loop.

Return Module with Flow Meter

Euro Style Com-pression Fitting

Crimpsert Loop Fitting (requires crimp ring)

Actuator Module (Black Plastic Cap)

Recommended Mani-fold Isolation Valve (not included with

manifold)

Balancing Module (Brass Cap)

Termination Module with Fill Purge Connection

Manifold Connector with 1” FPT Connection

Optional Air Vent (HRSMAV)

HRLA24V Mounted on Return Module for Individual Loop Actuation

Lock Ring

26

MANIFOLD CONNECTIONS

COPPER MANIFOLDS

The copper manifold line is available for those systems that require a minimum of zone and/or loop control. They are offered with Crimpsert connections on the inlet/outlet and loop connections for sys tems that require no loop isolation or balancing function and as buildup models that require the installer to join the manifold body, inlet/outlet fi ttings and loop valves by sweat soldering the components to geth er.

The Crimpsert copper manifolds are best used where all of the loops connected to a manifold pair are identical in length (maximum 10% variation) and will provide the most equal loop-to-loop fl ow-rate when connected in a reverse-return confi guration (fi rst in is last out and last in is fi rst out). This method yields the most consistent pressure drop through all loops con nect ed to the same manifold pair. No more than 12 loop tubes should be connected to a single manifold pair.

The buildup models feature isolation valves and bal anc ing valves for individual loop balancing control. Loop balancing is required when the length of loops con-nected to a single manifold pair vary by more than 10% and/or one or more loops connected to a man i fold pair are used to heat non-contiguous areas. Loop balancing is also required for rooms with higher heat loads at outside walls (due to a large window area or outside door(s)), or when more than one room is served by a manifold pair, especially when each room has a sig nifi cant ly dif fer ent heat load requirement.

Loop isolation andbalancing valves are available with either Crimpsert loop connec-tions (as sem bled with black copper crimp rings and crimp tools) or with compression fi ttings that require only a wrench to connect.

Flow-through Model

Closed-end Model

Crimpsert Copper Manifolds

Build up Man i folds

Crimpsert Isolation and

Balancing Valves

Euro Com pres sion Isolation and

Balancing Valves

Crimpsert Transition

Fitting

Crimp rings required for Crimpsert Con nec tions

Crimp rings required for Crimpsert

Con nec tions

Copper Manifolds Shown Mounted in

2x6 Wall with Mount ing Brackets (HRM5 or HRM7)

27

CAUTION! Overnight testing is not recommended as it results in erroneous test results. Large swings in ambient temperature will show dramatic changes in test pressure as the loop tubes expand and contract with temperature. Even the air inside the loops expands and contracts with temperature and will lead to erroneous

readings that could be indicative of a leak when no leak exists. Always start the test when the ambient temperature will remain relatively constant for the test duration.

CAUTION! If water is used for system pressure testing it must be protected from freezing if there is even a remote possibility that the ambient temperature will drop to freezing or below before the structure is completed and the system is operating. The antifreeze must be of suffi cient concentration to protect the system at least to the

lowest expected temperature. Antifreeze and water must be mixed well before fi lling the system. Failure to protect the system from freezing will result in ruptured tubing loops within the slab and at expansion joints and can crack the slab severely. Repair is very costly and must be avoided.

The system must be pressure tested before the loops are embedded in the slab or otherwise covered. As a minimum, the internal system pressure should be raised to 100 psig and held for at least 30 minutes. If it is a warm day and the sun has warmed the PEX tubing loops, there will be a slow expansion of the tubing that will show as a pressure decrease in the system. Depending on the ambient temperature, the pressure decrease could be signifi cant and may require re-pressurizing the system back to 100 psig and maintaining for longer than 30 minutes. As long as the temperature remains relatively constant, the pressure will stabilize if the system is leak-free.

If, after 2 hours test time the pressure cannot be stabilized, then there is probably a leak. Find and repair the leak and retest. It is paramount to system integrity that the loops are leak-free before covering. If a loop tube has been damaged during installation it is recommended to replace the entire loop and not install a repair coupling. Repair couplings are intended as a “last resort” repair during the pour when it is impossible to replace a damaged loop.

When pouring the fl oor covering, pressurize the system with 30 to 50 psig of air so that any damage occurring during the pour will immediately be evident and a repair can be made. Use only a Vanguard Crimpsert repair coupling of the correct size with heat shrink sleeve covering for loop repair. The crimps must be checked with a Go/No-Go gauge and the system must be re-pressurized and the repair checked for leaks before shrinking the heat-shrink tubing over the coupling and crimp rings and burying the repair in the slab.

SYSTEM PRESSURE TESTING

28

SYSTEM FILLING AND AIR ELIMINATION

After all of the loops have been connected to the manifolds, that portion of the system can be fi lled and purged of air. Alternately, the system can be pressurized with compressed air for leak de tec tion and to main- tain pressure on the system during the slab pour (see page 27) and the entire system (including trans fer pip-ing and the hot-water source) can be fi lled and purged at one time. Whether done in one or several stages, purging is a critical step since air entrapped in the system will inhibit or prevent fl uid fl ow through some or possibly all of the loops, zone piping or transfer piping.

The system must have at least one air vent device (Vanguard part# HRSMAV) and, for large-scale sys tems, there may be several air vents at key points in the system. The primary air-vent should be located between the water heating device and the circulator pump. This should be the point of lowest pressure in the system. Open the vent to the atmosphere while fi lling/purging the system to allow free escape of air. When fl uid be-gins to escape from the air vent, close it and continue fi lling/purging the system

It is recommended that the system be fi lled only with a water/antifreeze mixture of suffi cient con cen tra tion to protect the system from freezing down to at least the lowest expected temperature. Please realize that con-struction schedules can change and a poured slab may sit for some in de ter mi nate amount of time before the building is erected and an unprotected system can freeze resulting in cat a stroph ic damage to the PEX tubing loops, manifolds and the slab.

Loop and zone valves are important for purging as it allows individual control of purge fl ow to develop the needed fl uid velocity to force out air.

To affect the most effi cient purging, each zone and loop should be purged individually. The key to purg ing is to create a high-velocity fl ow through the tubing to force air out of the system. Cir cu la tion pumps are gen er al ly low fl ow and may not providethe needed velocity. Purging is best ac com plished with a purge cart. A purge cart is basically a container for mixing the water/antifreeze solution and a pump capable of de vel op ing a min i -mum velocity of 5 feet/second in the piping being purged. The fl uid is pumped into the system and is returned back to the mixing container until the return fl uid is essentially free of air bubbles line. Enough fl uid must be kept in the mixing container at all times during purging to prevent re-in tro duc tion of air into the system. Absolute air removal at the purging stage may not always be practical but removing as much air as possible during this step will help to ensure a properly operating system.

The Comap and Simplex manifolds have built in fi ll/purge con nec tions to fi t a standard garden hose fi tting. Other man i -fold types will need to be fi lled/purged through a different type of con nec tion. For pur pos es of fi lling/purging, a fl exible hose can be connected with a Crimpsert fi tting using ordinary hose clamps. Con nect the pressure side of the purge pump to the supply manifold and another line that returns to the mixing container to the return manifold. Close all of the loop iso la tion

Connect the supply and return lines from the fi lling/purging sys-tem to the built-in fi ll/drain con-

nec tions on the man i folds.

Fill/Purge Garden Hose Fittings

Fill/Purge Garden Hose

Fittings

COMAPSIMPLEX

Other manifold types require separate fi ttings to connect the

fi lling/purging system.

29

A simple fi ll/purge system consists of a container for mixing the water and antifreeze, a motor-driven pump and hoses to

connect to the radiant system.

valves on both manifolds and start the purge pump. Working one loop at a time, open the isolation valves on the supply and return manifolds and watch the return water fl ow back into the mixing container. Con tin ue to pump fl uid until there is little, if any air bubbles in the return fl uid stream. Close both isolation valves for that loop and open the valves for the next one. Continue this process for each loop on each zone.

When all manifolds and loops have been purged, the system can then be pressurized for leak tightness test-ing (see page 27) and then a lower pressure can be held on the system during the pour so that any inciden-tal loop damage can be located immediately and repaired.

If when the pour is complete and some time will pass before the supply/return piping is connected, de pres -sur ize the system and close all loop isolation valves and all zone isolation valves. When the remainder of the system is connected, fi lling and purging is done in exactly the same fashion as above but the zone isolation valves will be used to purge individual parts of the system instead of loop isolation valves. When fi lling/purging supply/return piping, leave all of the loop isolation valves closed to con cen trate the fl uid fl ow through the supply/return piping and manifolds. After all of the zones have been fi lled and purged, the loop isolation valves can then be opened.

If fi lling/purging will be done only after all of the piping is in place, follow the same procedure as out lined above but work one loop on one zone at a time using the isolation valves. When system purging is com plete, the purge pump can be used to pressurize the system to 15-20 psig.

Small amounts of air remaining in the system will eventually vent, however; too much air can con gre gate into a larger bubble and stop pumping action altogether. Also, some boilers can be damaged by excessive air in the system.

A fl ow meter in the transfer tubing is a good di ag nos tic tool and will show not only that fl uid is fl owing but will also show air bubbles (for clear meters) in the system. Remember that air in the system should be eliminated to the greatest ex-tent possible before startup to prevent op er a tion al problems later.

Each system must have an expansion tank to pro-vide for expansion and contraction of the fl uid as it is heated and cooled. Open expansion tanks are not recommended since they will introduce air into the system con tin u al ly. Use a tank with a fl exible bladder that separates the air-charge from the fl uid. Charge the air side of the tank 2 to 3 psig below the system charge pressure.

SYSTEM FILLING AND AIR ELIMINATION

30

Even the simplest system requires some form of control to sense the temperature of a room or rooms and turn the circulation pump on and off as required to maintain the proper temperature. All of the Vanguard control systems operate on low voltage 24 volt AC current.

The number and location of thermostats, zone or loop valves, temperature sensors, etc. must be known so that the necessary wiring can be installed throughout the structure prior to the wall fi nishing being applied. Typical control wiring is 18 AWG solid wire but the local electrical code may have different requirements. Control wiring must not be run parallel with telephone or AC lines or other sources of electromagnetic noise as this can affect the signal and may result in faulty operation. Twisted-pair or shielded cable, or running the wiring through grounded metal electrical conduit are options to prevent interference.

Due to size of some systems or necessity of control features, there can be a substantial number of control wires routed back to the mechanical room or other control location. Each wire (or pair as the case may be) must be marked as to the function that it serves. A mass of unmarked wires coming from different parts of a structure is a nightmare to sort out. Always mark each wire run as it is being installed to prevent unneeded problems.

One key to system comfort in large structures is providing suffi cient controls to provide on/off operation of not only the entire system but also of individual zones and even individual loops. South facing rooms with ample glass may require a separate thermostat to turn off the zone (or zones) when radiant gain from the sun is high. This on/off action can be provided by zone valves (or loop actuators) or individual circulation pumps.

Since each system is different, there are potentially thousands of control schemes and it is impossible to illustrate them all within the scope of this installation guide. Instead, we recommend that you contact Vanguard or the control system supplier for a detailed guide for the control unit(s) being utilized. The wiring schematics for the particular control being used must be consulted to ensure the proper wiring is installed.

SYSTEM CONTROLS

Outdoor Sensor

Simplifi ed control schematic illlustrates how multiple Zone or Room thermostats and outdoor and boiler temperature sensors provide feedback for automatic control of circulator(s) and/or Motorized Zone Valve(s). While not all systems will require this level of feedback and control, even simple systems need some form of thermostatic control to turn the system on and off.

Boiler Sensor

Whole House Control

Zone or Room Thermostats

Circulators and/or

Motorized Zone Valves

31

While there are any number of ways to pipe a radiant fl oor heating supply/return system, and it would be impossible to illustrate every potential confi guration, the schematics on the following pages represent several ideas that can be used "as is" or modifi ed to suit individual system needs. Also, there are some basic guidelines that should be followed to prevent operational problems with modifi ed piping layouts.

1) Each system or isolated part of a system needs an expansion tank. As the fl uid in the system is heat-ed and cooled, and during the off-season, there is a volume differential in the system that is best ac com mo dat ed with a bladder expansion tank. The charge pressure in the air-side of each expansion tank should be a few psig below the static system pressure.

2) Expansion tanks are best placed upstream of circulators.

3) An air vent or, preferably, an air separator, should be installed at a point in the system or each iso- lat ed part of a system where the pressure is the lowest (upstream of circulator) and the fl uid temp is the highest (just downstream of the water heating unit). This provides the most effi cient air removal.

4) Isolation valves at each circulator and manifold will facilitate fi lling and purging and simplify re place -ment of a failed or worn-out component.

5) Zone circulators are preferred to motorized zone valves in multiple-zone systems. Installing a cir cu -la tor on each zone provides for partial system operation in the event of a single circulator failure.

6) Using a single circulator and motorized zone valves on a large multiple-zone system may require a pressure activated bypass loop to prevent excessive head-pressure during single zone operation.

7) Never connect the system to the potable water system with an auto-fi ll valve. This is especially im- por tant for snow-melt systems. Unknowingly fi lling a leaky system with plain water can dilute the an- ti freeze concentration to a dangerously low level and can result in a system freeze-up. If an auto-fi ll is required, use a separate pressure tank with a water/antifreeze mixture of suffi cient con cen tra tion. Charge the tank above the static system pressure and connect it through a pressure-reducing valve (PRV).

8) Non-condensing boilers may require the addition of a manually or automatically controlled bypass loop to maintain return water temperature above the boiler manufacture’s recommendations to pre-vent con den sa tion of fl ue gases and acid production.

9) Size the circulator(s) for the portion of the system it (they) will be supplying. The primary circulator in a primary/secondary-circulator system must be sized for the total demand it must supply through the total length of piping in the primary piping circuit.

Schematics LegendThe illustrations below are used throughout the schematics section to defi ne system components.

PIPING SCHEMATICS

Ex pan sion Tank

Air Elimination

Device

Circulator Pump

Flow Check Valve

Isolation or Balancing

Valve

Motorized Zone Valve

3-Way Ther mo stat ic Mixing Valve

Manifolds and Radiant Panel

Loops

32

For small, single-zone systems using a condensing boiler, water heater, or when supplied from the domestic hot-water supply, the system can be piped similar to the schematic below. The fl oor panel supply water tempering is through a manually-set, 3-way thermostatic mixing valve. System on-off control can be accomplished through a single thermostat or may also incorporate outdoor and fl oor temperature sensors to offer more even room temperature.

When the radiant panel is supplied from the domestic hot-water system (when allowed by code), the expansion tank and air elimination device may be omitted. Some systems will require a balancing valve in the loop return to provide for return-side fl ow resistance to assure adequate return supply to the thermostatic mixing valve..

PIPING SCHEMATICS

Single Zone Simple System

When supplying the radiant system from the domestic hot water system, expansion tank and air elimination device may be omitted.

Condensing Boiler Water Heater or Supply from the Domestic Hot Water System

Balancing valve is optional but may be required to provide return-side fl ow re sis tance

MixedHot

Cold

33

The HRZCP1 Control Box simplifi es installations for single-zone systems up to 30,000 BTU. The zone pump, mixing valve and temperature control are all housed within the Control Box. The provided wall thermostat connects to the control box and provides on/off control by sensing room air and fl oor temperatures. The control also provides for high/low fl oor temperature limits.

When the system is supplied from the domestic hot-water system (when allowed by code), the expansion tank and air elimination device may be omitted. Some systems will require a balancing valve in the loop return to provide for return side fl ow resistance to assure adequate return supply to the thermostatic mixing valve.

PIPING SCHEMATICS

Single Zone Using Simply Radiant (HRZCP1) Control Box

When supplying the radiant system from the domestic hot water system, expansion tank and air elimination device may be omitted.

Condensing Boiler Water Heater or Supply from the Domestic Hot Water System

Balancing valve is optional but may be required to provide return-side fl ow re sis tance

Supplied Wall Thermostat Senses Room Air Temperature and Floor Temperature

HRZCP1Zone Con-trol

34

For larger systems with multiple zones, several HRZCP1 Simply Radiant Control Boxes can be supplied from a primary circulation loop off the hot water source. Each zone served by a Control Box then has its own fl oor and air temperature sensors to provide space temperature control. Please note, the diagram shown is not suitable for a noncondensing boiler. (See the diagram on page 40 for non-condensing boiler primary loop piping.)

When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops.

Some points to remember when installing this type of system- Check valves must be installed on the supply side of each secondary loop and optionally on each

return side- Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia.

of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop.

PIPING SCHEMATICS

Multiple Zones Using Simply Radiant (HRZCP1) Control Boxes

4 x pipe dia. min.8 x pipe

dia. min.

6” max.

HRZCP1Zone Control

HRZCP1Zone Control

Supplied Wall Thermostat Senses Room Air Tem per a ture and Floor Tem- per a ture

Secondary Loop

Primary Loop

Secondary Loop

Hot Water Source (if boiler, must be con dens ing type)

35

Multiple heating zones requiring a single zone supply temperature using motorized zone valves in place of zone circulators can be piped similar to the schematic below. By using a 3-way thermostatic mixing valve on the primary boiler loop and then adding secondary zone loops as needed, the system can provide a single supply temperature to all connected secondary loops. Zone valve systems should be piped with supply and return manifolds on the primary loop to insure proper circulation in the secondary loops. Please note that by relying on a single circulator pump only on the primary loop, that partial system operation in the event of a pump failure is not possible.

For even pressure balancing between secondary loops, the connection of the secondary supply and return lines to the primary manifolds should be piped in a fi rst-out/last-in fashion where the fi rst secondary loop on the supply manifold (closest to the supply pipe) is the last loop on the return manifold (furthest from the return pipe).

Additional zones can be added provided the heat source and the main circulator are properly sized for the entire demand. However, as the primary circulator size is increased, the need may arise to install a bypass loop in the primary circuit to prevent excessive pressure when only some of the secondary circuits are in operation.

The system shown below can also be piped to supply different temperatures to each secondary loop. By removing the thermostatic mixing valve from the primary loop and installing one on each secondary loop as required.

PIPING SCHEMATICS

Multiple Zone Single-Temperature System Using Motorized Zone Valves Installation

Condensing Boiler Water Heater or Sup-ply from the Do mes tic Hot Water System

Supply

Return

Service Valves(Optional)

NOTE! Large systems with numberous zones may require pressure controlled primary bypass loop to prevent exces-sive pressure.

Hot

Cold

Mixed

Balancing valve is optional but may be required to provide return-side fl ow resistance

36

Multiple heating zones requiring a single zone supply temperature can be piped similar to the schematic below. By using a 3-way thermostatic mixing valve on the primary boiler loop and then adding secondary zone loops as needed, the system can provide a single supply temperature to all connected secondary loops.

When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops.

Some points to remember when installing this type of system - Check valves must be installed on the supply side of each secondary loop and optionally on each

return side- Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia.

of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop.

PIPING SCHEMATICS

Multiple Zone Single-Temperature System Installation

Condensing Boiler Water Heater or

Supply from the Do mes tic

Hot Water System

Hot

Cold

Mixed

Balancing valve is optional but may be required to provide return-side fl ow resistance

Primary Loop

Secondary Loop

Secondary Loop

8 x pipe dia. min.

6” max.

4 x pipe dia. min.

37

Multiple supply water tem per a tures are achieved with 3-way ther mo -stat ic mixing valves as needed for different supply temperatures.

Condensing Boiler Water Heater or Supply from the Do mes tic Hot Water System

Hot

Cold

Mixed

Secondary Loop

Secondary Loop

Primary Loop

8 x pipe dia. min.

6” max.

4 x pipe dia. min.

Multiple heating zones requiring multiple zone supply temperatures can be piped similar to the schematic below. By using a primary boiler loop and then adding secondary zone loops as needed, the system can provide two or more zone temperatures by installing a 3-way thermostatic tempering valve on each secondary loop that requires a different temperature than the primary loop.

When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops.

Some points to remember when installing this type of system- Check valves must be installed on the supply side of each secondary loop and optionally on each

return side- Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia.

of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop.

PIPING SCHEMATICS

Multiple Zone Multi-Temperature System Installation

38

A motorized 4-way mixing valve provides automatic control of both loop supply water temperature and return boiler water temperature and is best suited to a non-condensing boiler but can also be used on condensing boilers. By sensing the temperatures of the loop supply and boiler return, the control ad-justs the position of the 4-way valve through the 4-way valve motor. Loop supply and boiler return are con stant ly adjusted to maintain the correct temperatures. The 4-way valve must be connected to the pri ma ry circulation loop through closely spaced tees not more than 6” apart.

The control may also be equipped with an outdoor sensor to provide anticipation control based on out-door temperatures.

PIPING SCHEMATICS

4-Way Mixing Valve Installation

CondensingBoiler

Outdoor Sensor(if equipped)

Heated Loop Supply Supply Sensor

Control

Valve Motor

Cooled Loop Return

4-Way Valve

Boiler Return Sensor

39

A Variable Speed Injection Pump is another method of providing tempered water from higher tem per a- ture boiler water. Injection mixing can be used to temper an entire single temperature primary loop by connecting it to a circulating boiler loop, or can be used to temper a secondary loop when connected to a primary loop.

The injection pump is controlled by a temperature sensor on the tempered loop and the speed of the pump is varied to inject enough higher temperature water into the cooled return water to achieve the desired mix.

A fl ow restriction valve is generally required on the injection return line to increase headloss in the circuit to match the pump’s output curve.

Loop or Zone Sup-ply

Heated Supply

Primary or Boiler Loop

Variable Speed Injection Pump

Primary or Secondary Loop

Loop or Zone Return

Flow Re stric tion

ValveBoiler

Return

Temperature Sensor

PIPING SCHEMATICS

Variable Speed Injection Pump Installation

40

Conventional, non-condensing boilers need protection of the return water temperature to prevent fl ue-gas condensation that can result in corrosion and lead to premature boiler failure. For non-condensing boilers, a 3-way thermostatic mixing valve can be piped as shown above. The mixing valve can be set to provide a tempered return water to the boiler to prevent fl ue-gas condensation from too cold return water. Consult the boiler manufacturers recommendations to set the mixing valve.

The remainder of the simple or primary/secondary system is piped the same as shown on the pro- ceed ing schematics.

Heated primary loop supply

Cooled primary loop supply

Non-condensing Boiler

Hot Cold

Mixed

PIPING SCHEMATICS

Non-Condensing Boiler Installation

41

While not required, fl ow-check valves on the return side of secondary loops will further prevent un- want ed circulation of the secondary loop during off-times even though the primary loop is operating. As an alternative to a fl ow check on the return side only, a thermal trap as shown below can be installed. The leg must dip at least 18 inches below the primary loop line to be effective.

Whether a thermal loop is used or not, the same close spacing of secondary loop supply/return tees must be followed (maximum 6 inches). Also, a drain fi tting may be fi tted to the bottom of the thermal trap to facilitate draining.

Thermal traps can replace fl ow-check valves on secondary loop return lines.

18” Min.

Heated primary loop supply

PIPING SCHEMATICS

Thermal Trap Installation

42

Follow these instructions carefully to ensure proper crimp connections.

APPENDIX A

RING SIZE MINIMUM MAXIMUM 3/8” 0.580” 0.595” 1/2” 0.700” 0.715” 5/8" 0.815" 0.830" 3/4” 0.945” 0.960” 1” 1.175” 1.190” 1 1/4” 1.431 1.445

MAKING CRIMPSERT CRIMP CONNECTIONS

The tubing should be cut squarely and evenly without burrs. Uneven, jagged or irregular cuts will produce unsatisfactory connections.

1. 2.

3.

4.

Slide the correct size crimp ring over the tubing end.

Insert the fi tting into the pipe to the shoulder or tube stop. Position the ring 1/8” to 1/4” from the end of the tubing.

4. The ring must be attached straight. Center the crimping tool jaws exactly over the ring. Keep the tool at 90° and close the handles completely.DO NOT CRIMP TWICE.

1/8 to 1/4”

CORRECT

INCORRECT

90°

5. You have a good crimp if the GO gauge fi ts the ring and the NO GO does not.

You have a bad crimp if the GO gauge does not fi t the ring or the NO GO gauge does fi t.

Bad crimps must be cut out of the tubing and replaced.

If you check the crimps with a micrometer or caliper, use the dimensions shown below.

CRIMP DIAMETER DIMENSIONS

Crimp outside diameters should fall within these dimensions when measured with a micrometer or caliper.

6.When checking crimps with a GO/NO GO gauge, push the gauge STRAIGHT DOWN over the crimped ring. NEVER slide the gauge in from the side. Do not attempt to gauge the crimp at the jaw overlap area. The overlap area is indicated by a slight removal of the blackening treatment.

43

DAILY TOOL CALIBRATION CHECK

Check tool calibration at least twice daily. Vanguard recommends at least the fi rst and last crimp of the day.

Accurately adjusted crimping tools are critical to the success of this fi tting system. If the crimped rings do not gauge properly, the tool needs adjustment. The method for checking the crimping tool for proper calibration is:

Slide the correct size “GO” side of the crimp gauge over the crimp ring in at least FOUR places. DO NOT gauge the crimp at the jaw overlap area.

If the “GO” side of the gauge fails to slide over the ring, the crimp tool requires calibration (ring is under crimped).

REMEMBER: A crimp tool which has worn parts may not calibrate. Return worn tools for repair or replacement.

If the “GO” side slides over the crimp ring, attempt to slide the correct size “NO GO” side of the gauge over the crimp ring in at least four places.

DO NOT gauge the crimp at the jaw over-lap area.

If the “NO GO” side of the gauge slides over the crimp ring, the crimp tool requires calibration (ring is over-crimped).

REMEMBER: A crimp tool which requires frequent calibration may require repair or replacement.

2. 3.

4. 5.

Assemble and crimp a fi tting (see page 5).

1.

APPENDIX B

44

The HCM compact crimp tools are generally not capable of over-crimping (the “NO GO” gauge fi ts over the crimped ring). However, normal wear may cause the crimp size to increase to above the maximum allowed (the “GO” gauge does NOT fi t). Tools manufactured prior to December 1996 must be returned for calibration if they do not crimp to the dimensions shown on page 5. Tools manufac-tured after that date have an adjustment feature built in and are easily identifi ed by a hex head on the back-pin, see Figure 1. These tools may be adjusted to decrease the crimp diameter up to fi ve times.

When an HCM crimp tool requires adjustment to a smaller crimp dimension, note the number to which the line on the hex head of the back pin points. (See Figure 1)

Carefully remove the retaining clip by inserting a small fl at blade screwdriver in the loop of the clip and turning the screwdriver.

From the clip end of the back pin, push it towards the tool body until the hex head on the other end of the pin just clears the body.

Rotate the pin until the line on the hex head points to the next higher number on the frame. Push the pin back into the frame and replace the retaining clip.

Crimp a test joint and check the crimped ring for proper sizing with a GO/NO GO gauge or by mea-surement (see page 5). Severely worn tools may require further adjustment. As the tool continues to wear with use, simply repeat these instructions as required.

To reduce crimp size, rotate Back Pin to Next Higher Number

Figure 1 Back PinRemove

Retaining Clip

CAUTION! The retaining clip is made from spring steel and may fl y off of the pin if not removed carefully, possibly causing eye damage and loss of the clip.

ADJUSTING “HCM” TOOLS

APPENDIX C

45

An accurately adjusted crimping tool is critical to the success of this fi tting system. If the crimped rings do not gauge properly, the tool needs adjustment.

The method for adjusting the HAR tool is:

ADJUSTING “HAR” TOOLS

1. 2.

3. 4.

HAR TOOL

Note the position of the notched head of the adjustment cam in relation to the Phillips-head retaining screw.

Open the tool handles.

Test the tool by crimping a joint and checking the crimped ring with the “GO” gauge. If the “GO” gauge slides over the ring then no further adjust-ment is needed. If the “GO” gauge will not slide over the crimped ring, then repeat the adjustment by rotat-ing the adjustment screw counter-clockwise an additional 1/2 notch and reinstalling the retaining screw in the other threaded hole.

Carefully remove the retaining screw and rotate the cam coun-ter-clockwise slightly until the retaining screw can be in-stalled in the other threaded hole. This provides about 1/2 notch of adjustment.

A tool adjusted to the middle of the crimp diameter range may reduce the frequency of calibrations.

Adjustment Cam

RetainingScrew

Reinstall RetainingScrew

APPENDIX D

46

Crimp a new joint after each ad-justment. Repeat the adjustment as necessary to calibrate the tool. The “GO” gauge shall slide over the crimped ring, the “NO GO” shall not slide over the crimped ring, or the crimp measures within the dimensions shown on page 5.

1. 2.

3. 4.

An accurately adjusted crimping tool is critical to the success of an insert fi tting system. If the crimped rings do not gauge properly, the tools need adjustment.

The method for adjusting the HAR34ST tool is:

Open the han-

dles and loosen

the BOTTOM ad-

justment screw

with the correct

size hex key

wrench.

If the “NO GO” gauge slides over the ring (crimp is too small) or if the crimp measures smaller than the minimum dimension (page 5), loosen the TOP adjustment screw 1/4 turn. Then tighten the

BOTTOM adjustment screw.

If the “GO” portion of the gauge will not slide over the ring (crimp is too large) or

the crimp measures larger than the maximum dimension (page 5), tighten the TOP adjustment screw 1/4 turn. Then tighten the

BOTTOM adjustment screw.

HAR34ST TOOL

ADJUSTING “HAR34ST” TOOL

A tool adjusted to the middle of the crimp diameter range may reduce the frequency of calibrations.

APPENDIX E

47

VANEX SERIES PEX REPAIR KIT

The Vanguard XLHRK3 (1/2”) and XLHRK4 (3/4”) fi eld repair kits are for Vanex series PEX tubing in slab-on-grade in stal la tions. While the best policy is to use only continu-ous lengths of tubing for plumbing lines, extenuating cir cum stanc es may dictate that a line be repaired due to a kink, puncture or other damage. If the line is damaged in more than one location, we strongly recommend that the entire line be replaced. Undamaged lengths of the re-placed line can be further utilized by cutting out the dam-aged section and using the remaining length(s) for other, shorter line(s). Please read and un der stand these instruc-tions before attempting a repair. Failure to follow these guidelines may result in leakage or failure of the repair. It is the responsibility of the user to read and un der stand these instructions in their entirety prior to attempting a repair.

1) Make a clean cut on both sides of the damaged area. Cut the tubing cleanly and square.

2) Slide the provided, 1” heat shrink tubing onto one end of the cut PEX and back a few inches.

Slide the provided crimp rings onto each end of the cut PEX and insert the fi tting into both tubes until the ends contact the tube stop on the fi tting. Position each crimp ring 1/8” to 1/4” from the end of the tubing. See Figure 1

Figure 1

3) Using the correct size PEX crimping tool, crimp each ring while holding the tool at a 90° angle to the tube with the jaws of the tool centered over the ring. After completing both crimps, check each one using the GO/NO-GO gauge (HAC34),. The GO portion of the gauge must slide over the crimped ring (except at the jaw overlap area) and the NO-GO portion of the gauge must not slide over the ring. If either or both of the completed crimps fail to pass a GO/NO-GO gauging, the con-nection must be cut out completely and re placed. Use a new fi tting and crimp rings and trim back the PEX tubing on both sides to eliminate the previously crimped portions. Make any necessary adjustments to the crimp tool and remake the

connection. Recheck the crimps with the GO/NO-GO gauge. Do not proceed until both of the crimps pass the gauging test.

4) Pressurize the repaired loop and check for leaks. We recommend a pressure of 100 psig and a mini-mum time of 15 minutes. If the joint passes both a gauging and a pressure test proceed to the next step. If the connection fails either test, cut out the connection, make any necessary tool adjustment and remake the connection.

5) Slide the length of heat-shrink tubing over the re-pair joint so that it is approximately centered. See Figure 2

Figure 2

6) Using a heat-gun on the low setting, apply heat to the shrink tube evenly with a constant motion. Never use an open fl ame! Continue heating until the shrink tube conforms to the shape of the joint and pulls down snugly around the tubing. See Figure 3.

Figure 3

7) The repair should be allowed to cool for a few minutes before fi nal placement of tubing.

APPENDIX F

48

CONTINENTAL UNITED STATES

OUTSIDE UNITED STATES

FAX

1-800-775-5039

888-747-3739

1-800-775-4068www.vanguardpipe.com

QHMN02VS 7.05

901 N. Vanguard StreetMcPherson, KS 67460