Table of Contents Introduction 3 Chapter 2: Operation 4 Chapter 3: Components 5 Chapter 4: Specifications 8

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3 Table of Contents Introduction 3 Application 3 Chapter 2: Operation 4 Manifold Function 4 Chapter 3: Components 5 Required Parts 5 Manifold without Actuators without Pressure Bypass Kit 5 Pump Kit (QHMPK_) 5 Accu Preassembled Manifold (QHAF-_) 5 Thermostatic Control for Pump Kit (QHMTCK) " Air Vent Kit with Drain(QHM_VKIT5) 6 Manifold Adapters (QHMMC_) 6 Manifold with Actuators Pressure Bypass Kit 6 Pressure Bypass Kit (QHMBPK) 6 Manifold Adapters (QHMMC_) 7 Actuators (QHMBMVDS) 7 Chapter 4: Specifications 8 Overall Dimensions 8 Chapter 5: Supply Line Sizing 10 Example 10 Chapter 6: Getting Started 17 Setup Actuator Assembly 17 Thermostatic Control Positioning 17 Actuator Assembly 17 Pressure Bypass Kit 18 Circuit Balancing 18 Thermostatic Locking Mechanism 19 Chapter 7: Wiring 22 Electrical Connection Example 22 QHMZ1P One Thermostat 22 QHMZ4P Multiple Thermostats 23 QHMZ4A Multiple Thermostats 24 Appendix A 25 Charts 25 Appendix B 27 Pressure Loss Charts

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5 Introduction Application Radiant heating systems supported by Zurn have gone through many technological advances in the past several years. One of the new revolutionary ideas in the radiant heating industry is integrating a system to supply fluid to radiant heaters like cast iron radiators, towel warmers, fin tube baseboard, etc. at a higher fluid temperature, while simultaneously providing Zurn tubing circuits underneath the floor with a cooler fluid temperature. Using the Zurn Mixing System with a preassembled manifold can help incorporate this latest technology into everyday life. The Zurn Mixing System functions by receiving fluid from the primary loop through the built-in injection valve feeding the fluid into the secondary loop through the built-in pump for the lower temperature in floor applications by mixing the supply return fluid at the manifold rather than in the boiler room as it has historically been done. The Zurn Mixing System can be very beneficial if used in one of the following applications: The system dimensions are limited. This manifold design enables the pump to be positioned in between the supply return header. If manifolds are located a significant distance from the heat source. 3

6 Chapter 2: Operation Manifold Function This section will help provide a basic understing of how the Mixing System works. This diagram demonstrates the flow through the Mixing System. FLOW FROM PRIMARY LOOP PUMP SUPPLY HEADER RETURN HEADER FLOW BACK TO PRIMARY LOOP When the injection manifold pump is turned off, the primary loop pump pushes fluid through the injection valve, return header, return valve, back to the primary loop without ever entering the Zurn Tubing in the radiant panel. This gives the primary pump the ability to supply fluid to multiple injection manifolds. The hot fluid from the primary loop enters into the Mixing System by way of the injection valve leaves through the return valve. These are the only two points in the manifold that are connected to the primary loop. Once the fluid comes to the injection valve at temperatures between ºF from the primary loop, it begins to flow through the system. The fluid first must flow through an injection valve, which limits the temperature of the fluid to travel through the heated floor system to a range of ºF. The thermostatic head (QHMTCK), which attaches to the injection valve, is supplied with a probe that connects to the supply header to ensure a more precise radiant panel supply fluid temperature. Then, the fluid flows through the pump is distributed to the heated loops via Zurn tubing through the supply header. Once the fluid returns from the heating loops goes through the return header, it can flow to two places. The majority of the flow is drawn up through the pump again becomes mixed with the hotter fluid coming from the injection valve to go through the radiant panel again. The minority of the flow goes toward the return valve, where it will essentially become integrated back into the primary loop to be reheated at the heat source. The injection valve has the ability to be set to a temperature that is ideal for radiant floor heating. Once this temperature is set, the valve will restrict the flow of excessive heat to the supply header in order to maintain the set temperature into the manifold. Actuators can control the flow of individual circuits in a radiant floor heating application. Actuators can be easily fitted onto the manifold. If actuators are used for multiple zones, installing the optional pressure bypass kit (QHMBPK) is recommended. It will help maintain a constant pressure throughout the system by relieving any excess pressure during the opening closing of the actuators. 4

7 Chapter 3: Components Required Parts There are two different configurations for the Mixing System. The configuration is dependent upon whether the Mixing System is zoned with actuators or not. If no actuators are being used in the Mixing System, then there is no need for the Pressure Bypass Kit. Manifold without Actuators without Pressure Bypass Kit The following kits parts are needed to assemble the Mixing System shown in Figure 1 (with no actuators or Bypass Kit) (feet) Figure 1 PUMP KIT (QHMPK - _ ) Figure Pump Performance MANIFOLD KIT (QHAF - _ ) AIR VENT KIT AUTOMATIC (QHMAAVKIT5) MANUAK (QHMAVKIT5) RETURN VALVE INCLUDED WITH THERMOSTATIC CONTRL QHMPK - _ (QHMTCK) (U.S. GMP) UP26-69 UP26-64 UP15-42 Use the pump curves to determine the correct pump kit to use for the manifold. The manifolds flow rate head loss is determined during the design phase of the radiant system. Pump Kit (QHMPK_) The pump kit is available in three different options: QHMPK-L is a low head pump injection mixing system that is recommended for systems with a flow rate of feet of head pressure. QHMPK-M is a medium head pump injection mixing system that is recommended for systems with a flow rate of feet of head pressure. QHMPK-H is a high head pump injection mixing system that is recommended for systems with a flow rate of feet of head pressure. All pump kits come with the following: Y connector with self-sealing tailpiece Pump isolating valve (2) valve with thermostatic option Self-sealing reducer (2) Straight connector T connector with self-sealing tailpiece Pump valve Accu Preassembled Manifold (QHAF-_) The following items are included with purchase of the manifold assembly. Supply header with balancing valves flow meters header with built-in on/off valves Vertical mounting bracket Available in 2-12 ports Thermostatic Control for Pump Kit (QHMTCK) The following items are included with the thermostatic control: Thermostatic head with sensor probe 5

8 Figure 3 1" Air Vent Kit with Drain (QHM_VKIT5) There is a choice of two different air vents - an automatic air vent (shown in Figure 1) a manual air vent. Both come with a drain. The following accessories must be added to the Mixing System to complete the assembly MANIFOLD CONNECTORS (QHMMC _ ) Manifold Connectors (QHMMC_) (See Figure 3) The manifold connectors must be purchased separately to connect the tubing to the headers. One pair of manifold connectors must also be purchased to connect the supply return tubing to the injection return valve. The size of the connector will depend upon the tubing size required for the supply return to the manifold (see Chapter 5). The manifold connectors are sold in pairs include: Figure 4 MANIFOLD CONNECTORS (QHMMC _ ) Compression nut Compression crimp ring Barbed fitting PUMP KIT (QHMPK - _ ) MANIFOLD KIT (QHAF - _ ) PRESSURE BYPASS KIT (QHMPBK) Manifold with Actuators Pressure Bypass Kit The following kits parts are needed to assemble the Mixing System shown in Figure 4. Use this configuration when actuators are being used for zone control. This configuration also uses QHMPK (Pump Kit), QHAF (Accu Manifold), QHMTCK (Thermostatic Control Kit). Pressure Bypass Kit (QHMBPK) The following items are included with the Pressure Bypass Kit. THERMOSTATIC CONTRL (QHMTCK) RETURN VALVE INCLUDED WITH QHMPK - _ Four way connection piece including drain valve automatic air vent Pressure bypass valve 1/2" straight fitting 3/4" straight fitting 3/4" Zurn barrier tubing Five way connector piece with drain valve temperature gauge 3/4" manifold connectors (2) 6

9 Figure 5 The following accessories must be added to the Mixing System when zoning with actuators utilizing the Pressure Bypass Kit. MANIFOLD CONNECTORS (QHMMC _ ) ACTUATORS (QHMBMVDS ) Manifold Connectors (QHMMC_) (See Figure 5) The manifold connectors must be purchased separately to connect the tubing to the headers. One pair of manifold connectors must also be purchased to connect the supply return tubing to the injection return valve. The size of the connector will depend upon the tubing size required for the supply return to the manifold (see Chapter 5). The manifold connectors are sold in pairs include: MANIFOLD CONNECTORS (QHMMC _ ) Compression nut Compression crimp ring Barb fitting Actuators (QHMBMVDS) (See Figure 5) Actuators are sold individually. They are used to start stop the flow through a loop. Actuators are grouped together by zone. The following items are included with the purchase of the actuator. Actuator Manifold adapter 7

10 Chapter 4: Specifications Overall Dimensions The diagram below the corresponding chart show the dimensions of the Mixing System with the Pressure Bypass Kit. It should be noted that the height of the Mixing System will remain the same, despite what pump has been purchased with the system. 17-3/8" [441] 6-1/4" [159] A Number of Loops Description A (inches) 2 2 Port Manifold (QHAF-2 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 17-3/4 3 3 Port Manifold (QHAF-3 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 19-3/4 4 4 Port Manifold (QHAF-4 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 21-3/4 5 5 Port Manifold (QHAF-5 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 23-3/4 6 6 Port Manifold (QHAF-6 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 25-3/4 7 7 Port Manifold (QHAF-7 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 27-3/4 8 8 Port Manifold (QHAF-8 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 29-3/4 9 9 Port Manifold (QHAF-9 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 31-3/ Port Manifold (QHAF-10 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 33-3/ Port Manifold (QHAF-11 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 35-3/ Port Manifold (QHAF-12 ), QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit, QHMBPK By-pass Kit 37-3/4 8

11 The diagram below the corresponding chart show the dimensions of the Mixing System without the Pressure Bypass Kit. It should be noted that the height of the Mixing System will remain the same, despite what pump has been purchased with the system. 15-1/2" [394] 6-1/4" [159] A Number of Loops Description A (inches) 2 2 Port Manifold (QHAF-2 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 14-7/8 3 3 Port Manifold (QHAF-3 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 16-7/8 4 4 Port Manifold (QHAF-4 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 18-7/8 5 5 Port Manifold (QHAF-5 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 20-7/8 6 6 Port Manifold (QHAF-6 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 22-7/8 7 7 Port Manifold (QHAF-7 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 24-7/8 8 8 Port Manifold (QHAF-8 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 26-7/8 9 9 Port Manifold (QHAF-9 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 28-7/ Port Manifold (QHAF-10 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 30-7/ Port Manifold (QHAF-11 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control Kit 32-7/ Port Manifold (QHAF-12 ), Automatic or Manual Air Vent, QHMPK Manifold Pump Kit, QHMTCK Thermostatic Control 34-7/8 9

12 SUPPLY PIPING FROM PRIMARY LOOP RETURN PIPING TO PRIMARY LOOP MS = MS MR MR = PS = PR = Chapter 5: Supply Line Sizing Example Use the worksheet below the diagram to the left to determine the diameter of the tubing to use for the supply return of the Manifold. Because the fluid temperature of the supply to the Manifold can be much higher than the fluid temperature going to the Radiant Panel the flow rate needed to supply the hotter fluid to the manifold is much less than the flow rate required from the Manifold to the Radiant Panel. This lower flow requirement enables the diameter of the tubing used for the supply return of the Manifold to be much smaller than what would be required for a conventional Manifold. This chapter explains each step of the worksheet below by walking through an example. Worksheet for Piping to Manifold (A) Total Rate of Manifold to Radiant Panel (A) = (B) Rate Needed. (See Chart, Appendix A) (B) = (C) Loss (FT-H 2 O). (See Chart, Appendix A) (C) = (D) Total Feet of Needed for Supply from the Primary Loop to the Manifold. (D) = (E) Number of Barbed 90º Elbows Branches of a Tee in Supply to the Manifold. (E) = (F) Number of Barbed Straight Fittings Runs of a Tee in Supply to the Manifold. (F) = (G) 1/2" = (D)+ [(E) X 8]+[(F) X 2.8], so ( ) + [( ) X 8] + [( ) X 2.8] = Ft. Of 1/2" (G) 5/8" = (D)+ [(E) X 8.5]+[(F) X 3.1], so ( ) + [( ) X 8.5] + [( ) X 3.1] = Ft. Of 5/8" (G) 3/4" = (D)+ [(E) X 9.2]+[(F) X 3.5], so ( ) + [( ) X 9.2] + [( ) X 3.5] = Ft. Of 3/4" (H) Loss (FT-H 2 O) Per Linear Foot of Each Diameter of at (B) (PR) Fluid Temperature( From Appendix B ) (I) Loss through (FT-H 2 O) for Supply to Manifold (I) = (G) X (H) (J) Loss (FT-H 2 O) Other Components in Supply to Manifold (K) Total Loss (FT-H 2 O) for Supply to Manifold (K) = (C)+(I)+(J) (L) Choose the Tubing Diameter That You are Going to Use for the Supply of This Manifold. Fill in the Values for (PS), (C), (K). (G) = (H) = (I)= (J)= (K)= (L)= Equivalent Tube Length Dia. 1/2" 1/2" 1/2" 1/2" (PS) 5/8" 5/8" 5/8" 5/8" (C) 3/4" 3/4 3/4" 3/4" (K) (FT-H 2 O) 10

13 When using the Accu manifold, there is a flow limit of 8. Figure 1 (A) Total Rate of Manifold to Radiant Panel This value is calculated during the design of the Radiant Heat system. The design can be done using Zurn Radiant Heat Design Software or by following the steps in chapters 9 through 11 in the Zurn Radiant Heating Design Application Guide. For this example we will use a flow rate of 6. (A) Total Rate of Manifold to Radiant Panel (A) = 6 PS Figure 1-A PS = 180ºF MS MR MS = 113ºF MR = 103ºF PR PR = 103ºF (B) Rate Needed This value is determined by calculating the four fluid temperatures located on Figure 1 then applying this data the flow rate in Step A to one of the two Charts in Appendix A. The fluid temperature at location (PS) is the temperature of the supply fluid coming from the primary loop of the Heat source before entering the injection valve. For this example we will use 180ºF. The fluid temperature at location (MS) is the temperature of the fluid going to the supply header of the manifold before entering the radiant panel. (This temperature requirement is determined during the design phase of the Radiant System.) This temperature is dialed in at the thermostatic head of the injection valve. Position * Full Open T(ºF) For this example, we will use position 3, 113ºF. The fluid temperature at location (MR) is the fluid temperature returning from the Radiant Panel entering the return header of the manifold. (This temperature is determined during the design phase of the Radiant System.) This temperature is typically 10ºF or 20ºF lower than the (MS) temperature. For this example we will use an (MR) temperature of 103ºF. The fluid temperature at location (PR) is equal to the fluid temperature at (MR) so for this example we will use a (PR) temperature of 103ºF. Figure 1-A: Example manifold with temperatures filled in at four locations. * Now you can write in the values for (PS), (MS), (MR), (PR) on the diagram located on page 10. Now we need to choose one of the two Charts in Appendix A. One chart is for a 10ºF Radiant Panel T the other is for a 20ºF Radiant Panel T. (This T is determined during the design phase of the Radiant Heat system.) It equals the fluid temperature at (MS) minus the fluid temperature at (MR). For this example, it is (113ºF - 103ºF = 10ºF). So, we will use the Chart at 10ºF Manifold T. See Appendix A: Chart at 10ºF Manifold T Now we need to determine which Temperature Difference column to use. This value is the fluid temperature at location (PS) minus the fluid temperature at location (PR). For this example, it is (180ºF - 103ºF = 77ºF). To be conservative we will round down use the 70ºF Temperature Difference column. Now we can find the value to use for the required through the injection valve by 11

14 Chart 1 Chart at 10ºF Manifold T Total Rate of Manifold 60ºF Temp. Difference 70ºF Temp. Difference Required Required locating the Step A value of 6 in the Total Rate of Manifold column following that row to the right until it intersects the 70ºF Temperature Difference column. So for this example the required through injection valve is (See Chart 1) See Appendix A: Chart at 10ºF Manifold T (B) Rate Needed. (See Chart) (B) = (C) Loss This value is located to the right of the value that was found in Part (B) (See Chart 2). For this example, the head loss through the injection return valve is feet of head. (NOTE: When applying this chart to the actual data, if the head loss value determined here is to high for a common pump, raise the temperature, if possible, at location PS, then recalculate). (C) loss (FT-H2O) through valve. (See Chart) For Parts D-F, see Figure 2: (C) = Chart 2 Figure 2 BASE- BOARD ZONE Chart at 10ºF Manifold T Total Rate of Manifold 60ºF Temp. Difference 70ºF Temp. Difference Required Required HEAT SOURCE BRANCH TEE FLOW CONTROL STRAIGHT FITTING 1' (D) Total Feet of Needed for Supply From the Primary Loop to the Manifold See Figure 2 above. The lengths for this example are marked by the dimension lines. For this example, the total length of the supply return is (1'+2'+13'+9') cumulated to 25'. (D) Total Feet of Needed for Supply from the Primary Loop to the Manifold. 2' ELBOW BRANCH TEE FLOW CONTROL: ADJUST TO CONTROL FLOW RATE INTO INJECTION VALVE 13' ELBOW (D) = 25 STRAIGHT FITTING 9' 12

15 (E) Number of Barbed 90º Elbows/Branches of a Tee in Supply to the Manifold This is simply the number of barbed elbows branches of a tee in the supply return to the manifold. This value will be used to determine the equivalent tubing length of the fitting. For this example, there are two elbows two tee branches. (See figure 2) (E) = = 4 (E) Number of Barbed 90º Elbows Branches of a Tee in Supply to the Manifold. (E) = 4 (F) Number of Barbed Straight Fittings/Runs of a Tee in Supply to the Manifold This is simply the number of straight barbed fittings runs of a tee in the supply return to the manifold. This value will be used to determine the equivalent tubing length of the fitting. For this example, there are two straight barbed fittings, indicated in Figure 2. These are the compression fittings that connect the tubing to the injection valve the return valve. They are indicated by squares in Figure 2. There are no tee runs in this example. (F) Number of Barbed Straight Fittings Runs of a Tee in Supply to the Manifold. (F) = 2 (G) Total Equivalent Tube Length of Supply to Manifold This part will determine the total equivalent tubing length in the supply return loop for the Mixing System. It will take into account the actual length of tubing, plus the equivalent length of any fittings in the loop. This can be found by using the equations shown in the table. Part G is completed below: (G) 1/2" = (D)+ [(E) X 8]+[(F) X 2.8], so (25) + [(4) X 8] + [(2) X 2.8] = 62.6 Ft Of 1/2" (G) 5/8" = (D)+ [(E) X 8.5]+[(F) X 3.1], so (25) + [(4) X 8.5] + [(2) X 3.1] = 65.2 Ft Of 5/8" (G) 3/4" = (D)+ [(E) X 9.2]+[(F) X 3.5], so (25) + [(4) X 9.2] + [(2) X 3.5] = 68.8 Ft Of 3/4" Equivalent Tube Length 1/2" 5/8" 3/4" (G) = Pressure Loss per Linear Foot - 1/2" - 80% Water/ 20% Propylene Glycol 40ºF. 80ºF. 100ºF. 120ºF. ft ft ft ft (H) Loss per Linear Foot of each Diameter of at (B) (from Appendix B) In order to determine this value, the charts from Appendix B must be examined. Go to the appropriate size tubing glycol percentage chart in Appendix B, for each tubing diameter. For this example, assume a 20% propylene glycol, 80% water mixture. Scroll down the flow rate column until you reach the value from Part B on worksheet. For this example, the flow rate is (from Part B) (round up to use the 0.9 row on the charts). Then go across the chart to the appropriate fluid temperature. To be conservative use the fluid temperature at the return valve which is location (PR) on Figure 1 (from Part B). For this example, (PR) = 103ºF, round down to use the 100ºF column on the charts. To determine the head loss per foot, scroll across the 0.9 flow rate row to the fluid temperature of 100ºF. They intersect at FT-H 2 O (see example to left). For this example, (H) = for 1/2". 13

16 Now apply the same flow rate fluid temperature used for 1/2" to the 5/8" 3/4" charts to determine their head loss per foot values. (For this example, 0.9 flow at 100ºF fluid temperature is used). The appropriate head loss per linear foot for each tubing diameter is shown below in the completed chart section of Part H. (H) Loss (FT-H 2 O) Per Linear Foot of Each Diameter of at (B) (PR) Fluid Temperature( From Appendix B ) 1/2" 5/8" 3/4 (H) = (I) Loss through for Supply to Manifold This step will determine the total head loss through the supply return tubing to the manifold. In order to do this, follow the equation below: By multiplying (G) x (H), the total head loss of the different tubing diameters can be determined. For this example: 1/2" = 62.6' x FT-H2O = FT-H2O 5/8" = 65.2' x FT-H2O = FT-H2O 3/4" = 68.8' x FT-H2O = FT-H2O (I) Loss through (FT-H2O) for Supply to Manifold (I) = (G) X (H) 1/2" 5/8" 3/4" (I)= (J) Loss any Other Components in the Supply to Manifold This part will take into account any head loss contributed by any other component not mentioned in this chart. In this example, there are no extra components that will contribute any extra head loss to the supply return to the manifold. (J) Loss any Other Components in the Supply to Manifold (J)= 0 14

17 (K) Total Loss (FT-H 2 O) for Supply to Manifold This is the total head loss of the supply return loop to the manifold. It will include the head loss through the injection return valve (Part C), total head loss of the fittings (Part I), any head loss through any other components (Part J). The total head loss can be found by using the following equation: Total Loss (K) = Loss (C) + Total Loss of (I) + Loss any Other Component in the Loop (J) For this example: 1/2" = = FT-H2O 5/8" = = FT-H2O 3/4" = = FT-H2O The chart below shows the example of the Total Loss of the supply return to the manifold for three diameters of Zurn tubing. (K) Total Loss (FT-H2O) for Supply to Manifold (K) = (C)+(I)+(J) 1/2" 5/8" 3/4" (K)= Figure 3 HEAT SOURCE BASEBOARD ZONE PRIMARY PUMP PRIMARY LOOP SECONDARY LOOP FLOW CONTROL FLOW CONTROL SECONDARY LOOP (L) Choose the Tubing Diameter That You are Going to Use for the Supply of this Manifold The primary pump is responsible for supplying the total flow rate required by the entire system. It must overcome the head loss of all the components in the primary loop plus the highest secondary loop (that it supplies) head loss (see figure 3). In the example, the head loss using 1/2" is not significantly higher than using 5/8" or even 3/4". In this case, the use of 1/2" for the supply return of this Manifold makes sense because it probably won t make a difference when sizing the primary pump. This is only an example. The installer's actual Manifold may calculate much higher differences in the head loss between 1/2", 5/8", 3/4" for the supply return to the manifold, thus affecting the size of the primary pump. Use the data in the chart to choose the diameter that makes the most sense. The chart below shows the diameter of the tubing chosen for this manifold with the values of (PS), (C), (K) next to it. So, the manifold in this example will use 1/2" for its supply return. The injection valve requires a minimum of at 180ºF fluid temperature. The Loss through the supply return to the manifold is 4.18 feet. (L) Choose the Tubing Diameter That You Are Going to Use for the Supply of This Manifold. Fill in the Values for (PS), (C), (K). (L)= Dia. 1/2" (PS) (C) (K) (FT-H 2 O) 180ºF

18 MS = 113ºF MS The entire chart diagram are now complete. Make copies of the blank chart diagram at the beginning of this chapter to use for sizing the supply return piping for multiple manifolds. SUPPLY PIPING FROM PRIMARY LOOP MR MR = 103ºF PS = 180ºF PR = 103ºF RETURN PIPING TO PRIMARY LOOP Worksheet for Piping to Manifold (A) Total Rate of Manifold to Radiant Panel (A) = 6 (B) Rate Needed. (See Chart, Appendix A) (B) = (C) Loss (FT-H 2 O). (See Chart, Appendix A) (C) = (D) Total Feet of Needed for Supply from the Primary Loop to the Manifold. (D) = 25 (E) Number of Barbed 90º Elbows Branches of a Tee in Supply to the Manifold. (E) = 4 (F) Number of Barbed Straight Fittings Runs of a Tee in Supply to the Manifold. (F) = 2 (G) 1/2" = (D)+ [(E) X 8]+[(F) X 2.8], so (25) + [(4) X 8] + [(2) X 2.8] = 62.6 ft. Of 1/2" (G) 5/8" = (D)+ [(E) X 8.5]+[(F) X 3.1], so (25) + [(4) X 8.5] + [(2) X 3.1] = 65.2 ft. Of 5/8" (G) 3/4" = (D)+ [(E) X 9.2]+[(F) X 3.5], so (25) + [(4) X 9.2] + [(2) X 3.5] = 68.8 ft. Of 3/4" (H) Loss (FT-H 2 O) Per Linear Foot of Each Diameter of at (B) (PR) Fluid Temperature ( From Appendix B ) (I) Loss through (FT-H 2 O) for Supply to Manifold (I) = (G) X (H) Equivalent Tube Length 1/2" 5/8" 3/4" (G) = /2" 5/8" 3/4 (H) = (I)= (J) Loss (FT-H 2 O) Other Components in Loop in Supply to Manifold (J)= (K) Total Loss (FT-H 2 O) for Supply to Manifold (K) = (C)+(I)+(J) (L) Choose the Tubing Diameter That You Are Going to Use for the Supply of This Manifold. Fill in the Values for (PS), (C), (K). 1/2" 1/2" 5/8" 5/8" 3/4" 3/4" (K)= Dia. (PS) (C) (K) (FT-H 2 O) (L)= 1/2" 180ºF

19 Chapter 6: Getting Started Circuit Balancing Setup Actuator Assembly Thermostatic Control Positioning The inlet temperature for the Mixing System can be easily controlled by positioning the thermostatic head (QHMTCK) on one of the numbers on the top of the head. Each number on the top of the thermostatic control is associated with a temperature, which is shown in the chart below: Position * Full Open T(ºF) Individual Circuit Actuator Assembly The thermostatic control has very accurate control over the temperature. The temperature of the fluid going into the system will only fluctuate as much as 1.8ºF. Actuator Assembly Zurn actuators (QHMBMVDS) should be installed onto the return header if the manifold is supplying multiple zones. Actuators can simply be installed on the return manifold by following these steps: 1. Remove the white valve shut-off caps. 2. Place the plastic adapter supplied with the actuator where the white valve shut-off cap was. 3. Push the actuator down on the plastic piece so that the chord is facing the back the actuator is rotated about 15º off from the center. 4. Rotate the actuator clockwise to lock in place. 5. Push the red button on the actuator. QHMBMVDS (Actuators) should be installed when one manifold is supplying multiple zones. 17

20 Pressure Bypass Kit If utilizing Zurn actuators in the Mixing System, the Pressure Bypass Kit (QHMBPK) should be purchased. Utilizing this kit will help relieve any excess pressure in the system. The injection manifold pump is sized according to the highest head flow rate that the Mixing System will encounter, meaning all of the actuators are in the open position. However, when one of the actuators closes, the fluid that would typically flow through that loop needs to go somewhere, it will end up flowing through the remaining open loops. This creates excess head flow through the zones, possibly resulting in noise throughout the system sending extra flow down loops. Installing the Pressure Bypass Kit (QHMBPK) will absorb the excess head pressure in the system caused by actuators constantly turning on off, therefore, maintaining consistent flow through the circuits. Below are steps on how to initially adjust the Pressure Bypass Kit (QHMBPK). 1. Turn on the system pump manifold pump. 2. Open all zone valve actuators by making the thermostats call for heat. 3. Close the Pressure Bypass by turning the white knob clockwise. 4. Adjust the flow rates to settings required by the design. This may take multiple adjustments (see circuit balancing). 5. Slowly open the Pressure Bypass counter clockwise until the flow meter readings change (it should indicate a decrease in flow). 6. Close the Pressure Bypass until the original flow settings are shown on the flow meters. A QHMBPK should be installed when actuators are being utilized in the Mixing System. Circuit Balancing The supply header has built-in mechanisms that allows the user to balance the flow throughout each individual circuit. Balancing is achieved by following the steps below. Be sure fluid is flowing through the system while attempting to balance the flow. 1. Remove the red cap over the balancing valve. 2. Turn the system pump on. 3. Then starting with the balancing valve fully open, close the allen screw the appropriate amount of turns until the proper flow rate is displayed on the flow meter. 4. Tighten outer lockshield against the allen screw. 5. Place the red cap back over the balancing valve. 6. Repeat for all circuits. 18

21 Step 1-a Thermostatic Locking Mechanism Once the proper head position has been set on the thermostatic head, it can either be locked so the head position does not move, or a maximum head position can be set. By setting the maximum head position the thermostatic head may be closed to reduce the temperature setting, but the temperature setting can not be increased. Continue to Step 1-a to lock the head or go to step 1-b to set the maximum head position. Step 1-a Put a mark on the removable cap that corresponds to the position that the head is to be locked. This enables the cap to be positioned properly when removed. The figure below will be locked at three. Proceed to Step 2. Step 1-b Step 2 Step 1-b Put a mark on the removable cap that corresponds to the maximum radiant panel fluid supply temperature setting another mark that corresponds to the set position (if different from the maximum position). This enables the cap to be positioned properly when removed. The figure below shows a maximum head position of three, a set position of two. Step 2 Remove the number cover with a small screwdriver. It is critical not to move the head position, or else the calibration could be lost the head would need to be positioned again. For this example, the head is positioned to number three. 19

22 Step 3 Step 3) The toothed metal ring must be removed from the inside of the thermostatic head. Remove the toothed metal ring by prying it s outer edge upward with a small screw driver. Continue to Step 4-a to lock the head or go to Step 4-b to set the maximum head position. Step 4-a Locking the Thermostatic. Confirm that the head is in the desired position place the toothed metal ring back inside the thermostatic head, with the tab situated inside the slotted area, below the arrow. The thermostatic head will now be locked in position. Proceed to Step 4. Step 4-a Step 4-b Setting the Maximum Position. Confirm that the head is positioned to the maximum radiant panel fluid supply temperature setting place the toothed metal ring back inside the thermostatic head, with the tab located to the left of the slotted area, below the arrow. This will stop the thermostatic head from turning past this set point. Step 5 Reassemble the number cover by snapping it back onto the thermostatic head. Make sure that it is replaced in the exact position that it was removed. Step 4-b Step 5 Cover snapped back into position that it was in as shown in Step 1-a when locking head. Cover snapped back into position that it was in as shown in Step 1-b when setting the maximum head position. 20

23 Chapter 7: Wiring Electrical Connection Example An integrated radiant floor heating system offers multiple options for controlling the system. The following diagrams shows some basic solutions to wiring options that may be encountered when wiring this type of heating system. The following wiring diagrams depict different ways of wiring the Mixing System with multiple accessories such as zone pumps actuators. QHMZ1P One Thermostat This diagram shows how to connect a one zone switching relay (QHMZ1P) with a thermostat the Mixing System. THERMOSTAT (QHSTH0) T1 DRAWING IS CONCEPTUAL. ALL LOCAL CODES MUST BE MET DURING INSTALLATION. QHMZ1P 1 ZONE SWITCHING RELAY POWER T. STAT ZP1 TO: 120 VAC POWER HEAT SOURCE TO: TT ON HEAT SOURCE POWER VENT (QHBPV ) SP1 EXPANSION TANK (QHWET ) PRESSURE REDUCING VALVE (QHWPRV3) BACKFLOW PREVENTER (QHWBP3) 21

24 QHMZ4P Multiple Thermostats This diagram shows how to connect a four zone switching relay to multiple thermostats the Mixing System. THERMOSTAT (QHSTH0) T1 THERMOSTAT (QHSTH0) T2 DRAWING IS CONCEPTUAL. ALL LOCAL CODES MUST BE MET DURING INSTALLATION. QHMZ4P FOUR ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY HEAT SOURCE POWER VENT (QHBPV ) EXPANSION TANK (QHWET ) PRESSURE REDUCING VALVE (QHWPRV3) BACKFLOW PREVENTER (QHWBP3) 22

25 QHMZ4A Multiple Thermostats This diagram shows how to connect a four zone actuator control valve to multiple thermostats the Mixing System. THERMOSTAT (QHSTH0) T1 THERMOSTAT (QHSTH0) T1 QHMZ4A FOUR ZONE VALVE CONTROL DRAWING IS CONCEPTUAL. ALL LOCAL CODES MUST BE MET DURING INSTALLATION. TO CONTROL BOARD ZONE 1 TO CONTROL BOARD ZONE 2 HEAT SOURCE POWER VENT (QHBPV ) EXPANSION TANK (QHWET ) PRESSURE REDUCING VALVE (QHWPRV3) BACKFLOW PREVENTER (QHWBP3) 23

26 Appendix A Charts Chart at 10ºF Manifold T 10ºF Temp. Diff. 20ºF Temp. Diff. 30ºF Temp. Diff. 40ºF Temp. Diff. 50ºF Temp. Diff. 60ºF Temp. Diff. 70ºF Temp. Diff. 80ºF Temp. Diff. 90ºF Temp. Diff. 100ºF Temp. Diff. Total Rate of Manifold Req. Req. Req. Req. Req. Req. Req. Req. Req. Req

27 Appendix A Charts Chart at 20ºF Manifold T 20ºF Temp. Diff. 30ºF Temp. Diff. 40ºF Temp. Diff. 50ºF Temp. Diff. 60ºF Temp. Diff. 70ºF Temp. Diff. 80ºF Temp. Diff. 90ºF Temp. Diff. 100ºF Temp. Diff. 110º Temp. Diff. Total Rate of Manifold Req. Req. Req. Req. Req. Req. Req. Req. Req. Req

28 Appendix B Pressure Loss Charts Pressure Loss per Linear Foot - 1/2" - 100% Water/0% Propylene Glycol (ft (ft) (ft) (ft) (ft) (ft) (ft) Pressure Loss per Linear Foot - 1/2" - 100% Water/0% Propylene Glycol

29 Appendix B Pressure Loss Charts Pressure Loss per Linear Foot - 1/2" - 80% Water/20% Propylene Glycol Pressure Loss per Linear Foot - 1/2" - 80% Water/20% Propylene Glycol