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Single Temperature Radiant System With Boiler Modulation and Optional DHW ControlThe Advanced Heating Controlincorporates low temperaturemixing, provides boiler modulation,and the option of domestic hotwater control with priority.Optional DHW sensor may be intank or on outlet piping. If boilerand DHW control is not needed,refer to Basic HeatingControl diagrams.MaterialQuantityStock CodeMixing Station112120-12125Advanced Heating Control116014Indoor Sensor116016Three Position Actuator for Station1180031-1/4" Stainless Manifold, # Outlets*115700 - 15710Thermostats*18002Powerheads315061Optional DHW Sensor116018Transformer 24V118008, 18020*Based on job requirementsA.H.C.A.H.CPrimary PumpSupply SensorS1P2System Pump3 PositionActuatorReturn Manifold3 Position ActuatorAir EliminatorBack Flow PreventorCold Water SupplyPressure Reducing ValveExpansion TankSupply ManifoldViega IM-PR-Concrete 030914 of 31

Multiple Temperature Radiant System With Boiler Modulation Note: If the heat loss andrequired water temperature variesthroughout a building, a multiplewater temperature system maybe required. To add an additionaltemperature system, pipe inanother Mixing Station with thenecessary controls.MaterialQuantityStock CodeMixing Station212120 - 12125Basic Heating Control216015Indoor Sensor216016Three Position Actuator for Station2180031-1/4" Stainless Manifold, # Outlets*215900 - 15910Zone Control218032Thermostats*18029 - 18031Powerheads*15061Optional DHW Sensor116018Transformer 24V118008, 18020*Based on job requirementsB.H.C.B.H.C.Primary Loop SizingCopper Pipe Size [inch]Flow Rate* [GPM]Heat Carrying Capacity 20,000450,000*Based on 6 FPS15 of 31Viega IM-PR-Concrete 0309

2.9 Zone WiringA manifold system allows anyone or more of the circuits tobe adapted for control by athermostat. The following aretypical zone wiring schematics.Detailed wiring diagrams areprovided with products.Important Note:Installation by a licensed electricianis recommended. Installation anduse of this equipment should bein accordance with provisions ofthe U.S. National Electric Code,applicable local code, and pertinentindustry standards.Wiring Schematic: One-Zone ApplicationDigital ThermostatC C R W NTC A/B24 VACTRANSFORMERFloor sensorWHITEBLACK120 VACINPUTNote: Digital Thermostats cancontrol up to 4 powerheads.Wiring Schematic: Multi-Zone ApplicationDigital ThermostatCCRWRWCNote: 4 Zone Control (18060)can operate 8 powerheads.6 Zone Control (18062) canoperate 16 powerheads.MainEnDSwiTCH4 & 6 Zone ControlTTboilErExTraEnDSwiTCHn/o CoM n/CSySTEM CirCulaTorDHw CirCulaTor120 VaCY1 Y2 R1 R2Viega IM-PR-Concrete 030916 of 31nEuTralHoT

CONCRETE SYSTEM INSTALLATION - CHAPTER 3Maximum Circuit Length3.1 Layout PlanningTo avoid waste and to have equalcircuit lengths, a carefully plannedlayout should be done. First,determine where the manifoldshould be installed. Remember themanifold must be accessible. Whencalculating the number of circuits,always round up. Keep the length ofeach circuit in the same room equal.Tubing 25 Btu’s / (hr x ft2)25 Btu’s / (hr x ft2 ) ble 3.1Calculating number of circuits:Total amount of tubing Maximum circuit length # of circuitsCircuit layout patterns for hydronic Radiant Floor HeatingExterior WallExterior WallExterior WallFigure 3.1aFigure 3.1bOne Wall SerpentineRoom has one exterior wallTwo Wall SerpentineRoom has two exterior wallsExterior WallExterior WallExterior WallFigure 3.1dFigure 3.1cThree Wall SerpentineRoom has three exterior wallsCounter FlowRoom has no exterior walls17 of 31Viega IM-PR-Concrete 0309

Manifold is located in the wall with access panelContinue serpentine pattern.Circuit 3Circuit 2Circuit 1Exterior WallFigure 3.1eUnheated areaManifoldRun supply tubing from red manifoldvalves into high heat loss areasfirst (i.e. closest to exterior walls,windows, sliders, etc.) and theninto the interior of the room.Higher water temperatures at theoutside wall will provide more BTUoutput where it is needed.Continue the circuits, laying themout in the same direction towardthe interior of the room.Figure 3.1fViega IM-PR-Concrete 030918 of 31

Tubing layout around jointsConcrete has very little flexibility andwill almost always crack. Jointingis one of the best ways to controlthe inevitable. Joint location, whichinfluences the radiant heating pipingdesign layout is generally specifiedby the architect.Typical Joint Locations Edge of thermal mass Side length 18' Sides less than 1:2 ratio Doorways Bays in L-shaped roomsIsolation JointsWhen installed against the concretefoundation at the perimeter ofthe slab, the joint material preventsthe slab from bonding to the walls.It also allows the slab to expandwithout cracking duringtemperature fluctuations.Control JointsControl joints force cracks to follow thepath of the joint. Without them, randomcracks will ruin the appearance andsometimes the usefulness of the slab.Slabs With Isolation And Control Joints1/2" Isolation joint(in radiant slabs 1/2"edge insulation is used)ControlJointsFigure 3.1hFigure 3.1gNote:Building or masonry supplycompanies sell 1/2" thickisolation joint material thatis precut to the thicknessof the slab.Isolation Jointsat pier and perimeterMinimize Penetration of JointsFigure 31iIncorrectFigure 3.1j19 of 31CorrectViega IM-PR-Concrete 0309

3.2 Concrete System InstallationFoam boardInsulation(1/2" min. R-2.5)Step 1Installing The Insulation Final grade should be accuratelyleveled. Cover grade with a polyethylenefilm (6 mill minimum).Insulation Recommendations When high water table - required Perimeter insulation - required At the thermal break - required(Between heated and unheatedslabs) Edge insulation - required In high heat loss conditions For small residential slabs( 2000 ft)Foam boardInsulation(1" min. R-5)Polyethylene Film(6 mil min.)FootingGravel3’GradeFigure 3.2aInsulation Benefits Increased response time Increased energy savings Improved thermal conductivity Decreased downward heat lossNote: Weigh down the foamboards to prevent wind uplift.In some jobs this can be done byinstalling wire mesh as soon asfoam boards are placed.Insulation recommended(R-5 min.).4 feet of perimeterinsulation is mandatoryto minimize highheat loss.Figure 3.2bNote: Check with local codes for requirements related to insulation.Viega IM-PR-Concrete 030920 of 31

Step 2Installing the TubingFasten tubing every two feet andthree times at each u-turn to holddown any return bends or othershapes created.It’s helpful to mark out portionsof each circuit directly on theinsulation using spray paint.The return bend can have akey hole shape to minimizethe tube spacing withoutkinking the tubing.Use bend supports in concrete.A bend support will help reducepossible damage to the tubingdue to the different expansionand contraction rates ofdifferent materials.Figure 3.2c21 of 31Viega IM-PR-Concrete 0309

Step 3Pressurizing the TubingPressurize tubing to 80 psi 24hours before pour and leavepressurized until slab is cured.Re-tighten any tubing couplingslocated in the slab area afterat least 12 hours ofsystem pressurization.Step 4Warming Up the SlabIt is best to warm the thermal massup slowly during start-up to helpprevent possible shock to the slab.In accordance with DIN 4725section 4, Viega recommends: Start warm up after concretehas reached its final set(curing complete). Set supply water temperatureto 77 F for the first three days. Increase supply watertemperature to the setpoint in gradual incrementsfor the next four days (maximumof a 50 F increase in a periodof 24 hours). Slab warm up should followthe concrete manufacturer’srecommendations.Step 5Testing the Concrete forExcessive MoistureThe polyethylene film test: tapea one foot square of 6 mil clearpolyethylene film to slab, sealingall edges with plastic moistureresistant tape. If, after 48 hours,there is no “clouding” or dropsof moisture on the undersideof the film, the slab can beconsidered dry enough forfinish floor applications.Drying times vary considerablywith location, season, interiortemperature/ humidity, etc.Follow the finish flooringmanufacturer’s recommendations.Concrete Thin-SlabsThe following may be added to themixture for flowability, and reducedshrinkage to minimize cracking;super plasticizer, water reducingagent, fiberglass reinforcing.Gypsum Thin-SlabsGypsum Thin-Slabs are usuallyinstalled after the walls have beenclosed in with drywall or otherfinish materials. The highly flowableGypsum mix fills in any gapsbetween the dry wall andthe subflooring reducing air leakageand sound transmission under walls.Note:Some installation methods call for the Thin-Slab to be constructedbefore any exterior walls or interior partitions are erected.To prevent bonding, all edges of the base plates that will be in contactwith the concrete slab should be coated with a suitable release agentcompatible with PEX tubing.Use a minimum of R-19 insulation under the plywood subfloor (refer tosection 2.7 Typical Cross Sections).Note: All tubing must be pressure tested prior to and during pour(Refer to section 4.2 Pressure Testing)Viega IM-PR-Concrete 030922 of 31

CONCRETE SYSTEM STARTUP - CHAPTER 44.1 Station and ActuatorInstallationMaterialProductQtyMixing Station1Three Position Actuator1Stainless Manifold, # outlets*1Basic Heating Control1Indoor Sensor1FostaPEX*Press Adapters4Compression PEX Adapters*1. Mount the Mixing Station usingthe mounting brackets.2. Make the press connectionfor the supply and returnlines to the Mixing Station onthe copper tee. Install teesas close as possible to keeppressure difference ata minimum.4. Use the SVC Compression orPEX Press Adapters to connectthe ViegaPEX Barrier lines tothe manifold.5. Remove the grey cap fromthe diverting valve on theMixing Station and screwthe actuator on hand tight*.*Based on job requirements3. Connect the supply andreturn lines by soldering on aViegaPEX Press adapter, thenpressing on ViegaPEX Barrieror FostaPEX .*Perform step 5 after the systemhas been filled and purged; refer tosection 4.2 for procedure.23 of 31Viega IM-PR-Concrete 0309

5.2 Purging and PressureTesting the SystemOperationPurging1. Attach drain hose to purgevalve hose connection on returnheader and open valve.2. Close all but one balancingvalve on supply header (underred caps, turn with 5mm allenkey). Close isolation ball valveon boiler return line. Removeplastic dust cap or temperaturecontroller from diverting valveand make sure that high-limit kitis fully open.3. Open boiler fast fill valve to purgecircuit. After purging first circuit,close red balancing valve andopen next one. Continue with onecircuit at a time until all circuitshave been purged.4. Close purge valve and openall balancing and boiler valves.Reset high-limit kit, and reinstallactuator onto diverting valve.the system will be eliminatedthrough the automatic air ventafter a few hours of constantcirculation.NOTE: If the system must bepurged again in the future for anyreason, the high-limit kit must bereopened during purging forfull flow.5. Any remaining air pockets inPressure TestingBefore the finish floor is installedthe radiant system must bepressure tested. Air or water maybe used as the medium.The following procedure isrecommended by Viega. Checkthe local building codes forcompliance or additionaltest requirements.Procedure:1. Double-check all connections tomanifold to ensure proper seal.2. Connect manifold pressurizationkit (1) to any purge valve (2).3. Pressurize the system to 80 psito detect potential nail or screwpenetrations.4. The system should hold the 80psi for a minimum of 24 hours.DivertingValveNote: If the tubing is damaged,repair punctured section with acompression coupling.Contractor: Maintain pressureduring the installation of the finishfloor to simplify leak detection iftubing is damaged.4.3 Initial BalancingMany times it is not possible to design the system using equal circuitlengths, so the system must be balanced in order to ensure adequate flowto each circuit on a manifold.(Refer to your Radiant Wizard design program for detailed balancing.)Procedure:1. Start with all valves wide open.2. To decrease flow, turn the balancing valve clockwise in small increments.Note: Remove red caps and turn balancing valves with included allen key.Valves are hidden to prevent tampering.Viega IM-PR-Concrete 030924 of 31

4.4 Adjusting the HighLimit KitOperationThe Mixing Station is providedwith a preinstalled temperaturehigh-limit kit. This kit isinstalled into the 3-way valve toallow a maximum supply watertemperature to be set. This kit mustbe unscrewed when purging thesystem, and should then be setaccording to the instructions below.25 of 31Viega IM-PR-Concrete 0309

4.5 Choosing aFinished FloorThere are three common types offinished floors used in residentialconstruction; wood floors, tile/vinyl,and carpet.When picking a finished floor, thelower the R-value, the better radiantheat will work. When using tile, theR-value will be low and thereforewill work very well with your radiantsystem. Vinyl flooring is anothercommon choice for kitchens andbaths and has a low R-value.Using carpet over radiant heatingrequires careful planning. Viega’srecommendation for a coveringover a radiant system is to notexceed a total of a 2.5 R-value (thecarpet pad plus the carpet itself).Remember that the pad and thecarpet are insulators and will restrictthe heat from getting into the room,so keeping the R-value of the padand the carpet low is a must. It maybe necessary to add supplementalheat or install hydronic baseboardsin rooms with heavy carpeting (seeViega’s Combiflex System).There are many questions regardinghardwood flooring over radiantheating. Armed with knowledge anda few precautions, hardwood floorsand radiant heat will work welltogether. There are twoimportant issues:1. Floor surface temperatures2. MoistureFloor Surface TemperaturesFor many builders, a reluctanceto install hardwood floors overradiant heat stems from problemsassociated with incorrect control ofthe floor surface temperatures.Viega IM-PR-Concrete 0309 Today, modern insulation andbuilding techniques allow aradiant floor to stay cooler thanthe floor of the average sunroom. The floor surface temperatureshould not exceed 85 F (refer tosection 2.4 to calculate the floorsurface temperature).Also be careful when using multipleor high R-value area rugs overhardwood flooring. Your radiantheating system must be designedwith this additional R-value takeninto account in order to performproperly. If the system wasdesigned for bare wood flooring,adding area rugs may lead toa situation where heat outputis diminished.If the moisture content is relativelyhigh near the top surface of theplank, it will crown downward onthe edges.Wet ExpansionSources from below: Inadequate moisture barrier Ground water wicking throughthe slab Unsealed subfloorMoistureSources from above:Allow the radiant system to run forat least a week before installingthe hardwood. This will ensure thatthe subfloor is dry. Wood flooringshould be acclimated to the job sitebefore installation. When checkingthe moisture content of the subfloorand wood flooring with a moisturemeter, aim for a reading of 6%to 8%. Moisture will affect thehardwood floor with or without aradiant system. High relative humidity Moisture absorption causes woodto swell. Moisture loss causes woodto shrink.If the moisture content of the woodis relatively high near the bottomof the plank, cupping upward willoccur exaggerating cracks.Dry Shrinkage26 of 31Both solid plank flooring andengineered wood floors areacceptable choices overradiant heating.Choosing narrower planksand harder woods minimizesdimensional change in thewood. Engineered wood flooringusually has less expansion andcontraction and can be a goodchoice to minimize gapsbetween planks.Note: Follow the flooringmanufacturer’s installationmanual or NOFMA’s (NationalOak Flooring ManufacturersAssociation) manual.

4 Inch Slab on or below Grade Application with 6" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R5 insulation below the slab.Figure Appendix A.a4 Inch Slab on or below Grade Application with 9" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R5 insulation below the slab.Figure Appendix A.b27 of 31Viega IM-PR-Concrete 0309

4 Inch Slab on or below Grade Application with 12" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R5 insulation below the slab.Figure Appendix A.c1-1/2 Inch Thin-Slab with 6" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R19 insulation below theFigure Appendix A.dViega IM-PR-Concrete 030928 of 31subfloor.

1-1/2 Inch Thin-Slab with 9" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R19 insulation below the subfloor.Figure Appendix A.e1-1/2 Inch Thin-Slab with 12" Tubing SpacingBased on 68 F room temperature with 1/2" ViegaPex Barrier tubing with R19 insulation below the subfloor.Figure Appendix A.f29 of 31Viega IM-PR-Concrete 0309

Section thru fibrous expansion joint (typical)6 - 8" Typ.Fibrous expansion joint: Coordinatewith architectural drawings forexpansion joint locations.ViegaPEX tubingSleeving (piece ofpolyethylene or PVC pipe)InsulationFigure Appendix C.aGravelSection thru metal expansion joint (typical)Metal expansion joint: coordinatewith architectural drawings

3 Concrete System Installation. 3.1 Layout Planning 17 3.2 Concrete System Installation 20. 4 System Start-Up. 4.1 Station and Actuator Installation 23 4.2 Purging and Pressure Testing 24 4.3 Initial Balancing 24 4.4 Adjusting the High Limit Kit, Diverting Valv