Weil Mclain Radiant Heat

AlumiPex
Controls
q
Tubing Radiant Tubing

Pumps
q
Wiring
Design Guide
Part No. 650-000-240/1098
AlumiPe Tubing AlumiPex Radiant Tubing
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Hazard definitions The following defined terms are used throughout this Guide to bring attention to the presence of
hazards of various risk levels, or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage. Indicates presence of hazards that will or can cause minor personal injury or property damage. Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.
Codes and standards
This Guide is provided for general information only. The building or heating system designer is responsible for all design details and for compliance with all building codes, local and national. Refer to AlumiPex Technical Information sheets for specific certifications and listings of AlumiPex Radiant Tubing. AlumiPex Radiant Tubing is not certified for potable water applications. Consult local requirements before installing a radiant heating system. Install AlumiPex tubing following all of the applicable codes and all specifications and methods prescribed by the building designer and heating system designer. Do not use AlumiPex Radiant Tubing to conduct natural gas. Such an application could result in severe personal injury, death or substantial property damage. Material referenced in this Guide is subject to change without notice. Review all equipment installation instructions for compatibility before installing. Install all equipment in accordance with the equipment manufacturers instructions and all applicable codes. Failure to do so could result in severe personal injury, death or substantial property damage. Do not use AlumiPex Radiant Tubing in potable water or in systems which use boiler system water for potable use. The tubing is not approved for domestic water use. In combination space heating/potable water heating applications, chemical or biological contamination in the system water is possible and could result in severe personal injury, death or substantial property damage. Use only AlumiPex Fittings with AlumiPex Tubing. Use of any other method can result in severe personal injury, death or substantial property damage. Finished flooring: Use only finished flooring approved by the flooring manufacturer for use with heated floors. Failure to follow this guideline could result in substantial property damage. Do not expose AlumiPex Radiant Tubing to petroleum products or solvents.
Part Number 650-000-240/1098
Controls q Pumps q Wiring Installation Guide
Contents
I II Overview .................................................................................................................................. 4 Piping & control methods
Three temperature control ...................................................................................................... ..................................................... 5 Exceptions .................................................................................................................................................................................... 6 Piping/ controlling methods ......................................................................................................................................................... 6 Method 1 - Variable speed injection mixing ............................................................................................................................... 7 Method 2 - Dual three-way valves .............................................................................................................................................. 9
III IV
Primary/secondary piping
Why use primary/secondary piping? ........................................................................................................................................ 10 Primary/secondary piping tips ................................................................................................................................................... 12
Zoning radiant heating systems

Combining spaces for zoning ..................................................................................................................................................... 15 Using zone valves and/or valve actuators ................................................................................................................................ 15 Combining circuits on manifolds ............................................................................................................................................... 16 Control circuit transformer sizing ............................................................................................................................................... 16
V VI
Control strategies general

Outdoor reset .............................................................................................................................................................................. 20 Constant circulation .................................................................................................................................................................... 21
Injection mixing components

Weil-McLain IPC Injection Pump Control ................................................................................................................................... 22 Weil-McLain IPP-150 Injection Pump Panel .............................................................................................................................. 24
VII Determining flow rates

Primary circuit flow rate ............................................................................................................................................................. 26 Injection pump flow rates .......................................................................................................................................................... 30 Secondary circuit flow rates ...................................................................................................................................................... 31
VIII Determining head loss

Equivalent length .............................................................................................................. .......................................................... 32 Head loss (series circuits) .................................................................................................... ...................................................... 32 Determining head losses for circuits in parallel ............................................................................... ......................................... 35 Head losses for AlumiPex tubing circuits ....................................................................................... .......................................... 36
IX X XI
Selecting pumps
Method 1 - select pump from pump curve ............................................................................................................................... 39 Method 2 - select pump from quick selector curves ................................................................................................................ 41
Piping radiant circuits ........................................................................................................... 46 Domestic water heating ....................................................................................................... 52

System CP-1 SystemC P-2 SystemC P-3 SystemC P-4 System CP-5 SystemC P-6 SystemC P-7 SystemC P-8 System CP-9 System CP-10 System CP-11 System CP-12 Adding a small zone of radiant heating to an existing baseboard heating system ........................................................................................................... 56 GV boiler supplying an injection pump panel ................................................................................................................................................................. 60 Conventional boiler supplying an injection pump panel .................................................................................................................................................. 64 Two-temperature radiant heating system using two injection pump panels ................................................................................................................... 68 Two-temperature radiant heating system using one injection pump panel and a mixing valve ...................................................................................... 72 Radiant heating and domestic water heating with conventional boiler - DHW as a secondary circuit ............................................................................ 76 Radiant heating and domestic water heating with GV boiler - DHW as a secondary circuit ............................................................................................ 80 Radiant heating and domestic water heating with conventional boiler - independent DHW operation ........................................................................... 84 Radiant heating and domestic water heating with GV boiler - DHW through diverting valve .......................................................................................... 88 Radiant heating, domestic water heating and baseboard heating with conventional boiler ............................................................................................ 92 Radiant heating, domestic water heating and baseboard heating with GV boiler ........................................................................................................... 98 Radiant heating, domestic water heating and baseboard heating with multiple boilers ................................................................................................ 104
XII Radiant heating system examples ...................................................................................... 54
XIII Appendix .............................................................................................................................. 110

Part Number 650-000-240/1098
Overview
Whats in this guide?
We intend this Guide to provide system designers with the information needed to select and specify controls, pumps and piping for AlumiPex radiant heating systems.
Determining flow rates provides suggestions on how
to calculate the flow rates needed for each type of circuit in a radiant system - for multiple purpose systems as well as for radiant heating only.
Determining head loss provides means for calculating head losses in copper and steel piping and in AlumiPex radiant tubing circuits. Selecting pumps provides pump curves for common
The most important message in this guide is the need to control not just space and supply water temperatures, but to design and install systems that regulate the boiler return water temperature.
Piping & control methods provides you a choice of
two basic piping/control designs which meet the needs of AlumiPex radiant heating systems and the needs of noncondensing boilers. These are

pumps. This section includes a new approach to pump sizing - curves for , and 1 AlumiPex tubing and through 2 copper piping that show pump GPM vs system equivalent length for common circulators (pumps). This allows you to directly select a pump based on your system equivalent length and flow rate, or to see what will happen if you place a different pump on your system, without having to draw a system curve.
Piping radiant circuits and Domestic water heating
Variable speed injection mixing (preferred method) Dual three-way valves (alternate method)
Though other designs can accomplish similar performance, we have chosen to concentrate on a limited selection to assure coverage in depth.
Primary/secondary piping outlines the reasons for using
introduce the final section of this guide, devoted to specific methods for piping and controlling radiant systems and multiple purpose systems (radiant heating plus domestic water heating and baseboard heating). These sections provide the background for the radiant heating piping examples which follow.
Radiant heating examples includes 12 examples of radiant heating systems, including multiple purpose systems for domestic water and baseboard heating. These do not represent all of the possibilities, but show some effective applications of the principles discussed in this Guide. Note, in particular, the emphasis on threetemperature control control the boiler return water temperature (to protect the boiler) in addition to space and supply water temperatures.
primary/secondary piping and some suggestions on how to apply it.

Zoning radiant heating systems provides guidelines for combining spaces in zoning and how to apply AlumiPex zoning components. Control strategies general presents the case for
outdoor reset and discusses continuous (or extended) circulation in radiant heating, along with some guidelines for setting up reset controls.
Injection mixing components gives a brief introduction to the Weil-McLain Injection Pump Control, the IPC, and the Injection Pump Panel, the IPP. For further information on these components, refer to the Injection
Pump Panel/Injection Pump Control (IPC) Installation and Operating Manual.
This guide does not include radiant heating heat loss calculations or tubing placement design. These are handled in separate publications. Weil-McLain currently provides a computer-based sizing system the AlumiPex Radiant Expert program. We recommend using the A.R.E. in combination with this guide for the most comprehensive coverage of radiant heating design with our products.
Part Number 650-000-240/1098
II
Three temperature control
Piping & control methods

Piping and control designs must not only regulate space comfort - they must also: assure the correct water supply temperature to the heating system. protect noncondensing boilers from flue gas condensation and thermal shock. So, piping and controls must regulate three temperatures x Space temperature y System supply temperature z Boiler return temperature
Regulate the space temperature by: sensors located in the space and outside (if outdoor reset is used) correct placement of radiant tubing and other heating units regulation of heating water temperature and flow Regulate the system supply temperature by: using a control designed for radiant heating using primary/secondary piping as described in this guide using variable speed injection mixing or a correctly placed three-way valve Regulate the boiler return water temperature by: using primary/secondary piping as described in this guide using a variable speed injection mixing system or correctly placed three-way valve Why regulate the boiler return water? Flue gases contain water and acid vapors. When the flue gases contact a surface below the dewpoint temperature, acid and/or water will condense on that surface. This could damage the boiler and lead to premature failure. Controlling the return water at or above 130 F will provide protection for most boilers. Radiant heating systems typically operate with supply water below 130 F and return water from 90 to 110 F. Water this cool will cause condensation damage and may cause thermal shock as well. The controls and piping must be designed and installed to return water to a noncondensing boiler at or above 130 F to prevent condensation and possible thermal shock. Failure to follow this guideline could result in substantial property damage.
Part Number 650-000-240/1098
II
Piping & control methods - continued

The most common heating source for radiant heating systems is a noncondensing boiler. The boiler may be cast iron, steel or copper, but will usually require a minimum return water temperature, as specified by the boiler manufacturer. If the manufacturer states a minimum return temperature - regardless what that temperature is - the piping and controls must assure the water temperature does not return to the boiler below the minimum. The risk of not controlling the temperature is damage to the equipment - ranging from minor corrosion to complete failure of the heat exchanger.
Piping/controlling methods
This Guide focuses on the two preferred methods of regulating space, supply water and return water temperatures Method 1 - Variable speed injection mixing. Method 2 - Dual three-way mixing valves.
Method 2 may, in some cases, have a lower first cost than Method 1. But Method 2 cannot provide outdoor reset control without motorized valves - this could cause Method 2 to be more costly than Method 1.
Exceptions
There are exceptions to the need for return water temperature control - but ONLY for cases where the return water temperature will naturally remain above the minimum specified by the boiler manufacturer. An example is the special case of floor heating using tubing suspended in the joist bays (not stapled to the floor). For such systems, the supply water temperature is usually 160 F or higher. Moreover, the radiant system has low mass because the tubing is not in contact with the floor. So, these systems will behave similarly to finned tube baseboard systems - return water temperature will nearly always be above 130 F, and any periods of lower return temperature will be brief. Such exceptions are not illustrated in this Guide (except for System CP1, discussed below) to avoid confusing the issue. Most radiant heating installations require
return water control because most of the heating sources require a minimum.
Alternative piping/controlling methods

This Guide addresses only these two methods in order to provide coverage in depth. Other methods can be used and are covered in supplementary documents. No alternative is as effective or flexible, however, as Method 1 - variable speed injection mixing. The WeilMcLain IPP Injection Pump Panel and IPC Injection Pump Control provide exceptional control and a wide range of control options.
Interchangeability
Figures 2 and 3 are simplified schematics of Methods 1 and 2, respectively.
Note the piping contained in the dotted rectangles of these schematics. Wherever an IPP Injection Pump
You will find an exception to regulated return temperature in Radiant heating system examples, System CP1. This special case applies to a small radiant circuit added to an existing baseboard heating system. For this situation, return water protection is unnecessary because the radiant circuit will not reduce the return water temperature significantly.
Panel (Method 1) is shown in piping diagrams in this Guide, you can substitute the piping in the dotted rectangle in Figure 3. That is, the dual three-way mixing valves, piped as shown, will provide the same regulation and protection as Method 1. Bear in mind, if outdoor reset is desired with Method 2, a motorized valve and appropriate controls will be required.
Part Number 650-000-240/1098
Method 1 Variable speed injection mixing

Injection mixing uses a pump to inject hot water from the primary (boiler) circuit into the secondary (radiant heating) circuit. The amount of heat injected is regulated by varying the pump speed and hence the flow rate. For each GPM of water injected at A, an equal amount of water exits the heating circuit at B, and mixes with the primary (boiler) loop supply water at D. So the injection pump pulls heat from the boiler (primary) loop and injects it into the secondary (heating) circuit.
Figure 1 is a simplified injection mixing circuit. The injection pump pulls hot water from the primary loop at C. This water (at temperature TH) is injected into the secondary (heating) circuit at A, where it mixes with the cooler return water (temperature TR). The result is heating circuit supply water at temperature TS. If the injection flow rate, FI, is increased the supply water temperature will increase. If the injection flow rate is decreased the supply water temperature will decrease.
The return water from the secondary (heating) circuit lowers the water temperature returning to the boiler. So the IPC Injection Pump Control monitors boiler return water temperature (see Figure 2) as well as heating circuit supply water temperature. Should the boiler circuit return water temperature approach 130 F, the IPC slows down the injection pump. This raises the temperature returning to the boiler because less cool heating circuit water is injected into the boiler (primary) circuit.
Figure 1 Radiant heating Method 1 Injection mixing
Boiler loop return
Boiler loop supply
TH
Balancing valve
TH FI
Injection pump
TR
System return
TS FS
System supply
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Piping & control methods - continued

Method 1 Variable speed injection mixing
Figure 2 is a typical piping schematic for injection mixing in a radiant heating system. Injection pump speed is controlled by the Injection Pump Control drop (DTS), system return temperature (TR) and supply water temperature (TH) available from the boiler. The formula for F1 is DTS F1= FS x (TH TR) Injection pumps are generally much smaller than system pumps. For example, for 110 F system supply and 10 F system drop (100 F return temperature), with 180 F boiler supply temperature, the injection flow rate is only 1/8 as much as the system flow rate, since F1= FS x 10 (180 - 100)
Pump speed is increased when the system supply

temperature drops below target value.
The pump is slowed as the system supply

temperature rises or when the boiler return water temperature drops below the preset limit.
The balancing valve in the injection circuit is used to

provide some pressure drop against the injection pump, improving flow control. Maximum required injection pump flow rate, F1, is related to system flow rate, FS, system temperature
Refer to Section VI, Injection mixing components, for application and sizing information.
Figure 2 Radiant heating Method 1 Injection mixing, typical

Fill
Boiler loop pump
(The piping enclosed in the dotted rectangle represents the components included in a Weil-McLain IPP Injection Pump Panel)
2 to 4 pipe diameters
Expansion tank
Boiler return sensor
IPC
Injection pump
Injection Pump Control

Outdoor sensor
(optional)
System supply sensor
Manifolds
Boiler
Heating system pump

Radiant loops
Part Number 650-000-240/1098
Method 2 Dual mixing valves

Figure 3 is a schematic of the dual three-way mixing valve system. This is intended as an alternate to injection mixing. We suggest using this method only if a cost analysis indicates a noticeably reduced installed cost. The three-way mixing valves can be self-contained, remote bulb operated or operated by an actuator (electric or pneumatic, for example). As shown if Figure 3, the heating loop incorporates a mixing valve piped to regulate the system supply temperature. If the mixing valve is motor-operated, it can be used to provide outdoor reset of the supply temperature to the system. The mixing valve in the boiler loop regulates the return water to the boiler. This valve should normally be set at 130 F (or as specified by the boiler manufacturer). Figure 3 Radiant heating Method 2 Dual mixing valves (The piping enclosed in the dotted rectangle can be substituted for an IPP Injection Pump Panel wherever the IPP is shown in this guide)
Fill
With the piping as shown, the heating system may operate at any desired temperature without risk of causing condensation in the boiler. Likewise, the boiler supply temperature may be set as high as desired without causing excessive temperature in the heating system because the heating system three-way valve controls the temperature sent to the system.
Exception: Control of boiler return temperature should
not be necessary for finned tube baseboard heating systems which have a small, low mass radiant loop as shown in example system CP-3. Small means the radiant circuit load must not exceed 10% of the boiler output. This radiant application must only be for suspended floor applications not for slab applications (neither thick nor thin slab).
Boiler loop pump
Mixed Cold Hot
Expansion tank
Cold Mixed Hot Manifolds
Heating system pump
Radiant loops
Part Number 650-000-240/1098
III
Why use primary/ secondary piping?
Primary/secondary piping
Traditional piping for residential hydronic heating uses series loop or two-pipe piping. Commercial systems are usually two-pipe design. These piping designs lack the versatility and efficiency needed for today's systems, particularly for radiant heating. Use primary/secondary piping for radiant heating (and for any system using outdoor reset or energy management). Look at Figures 4 through 7 for a comparison of a traditional two-pipe system to a primary/ secondary system. Notice that the system pump must provide all the flow needed for every branch in a traditional two-pipe system. But the flow in each secondary circuit (branch) of the primary/secondary system is individually controlled by the loop components.
Advantages
This discussion emphasizes the advantages of primary/secondary piping in radiant heating systems. You should see that the versatility of primary/secondary designs and the ability to more easily control temperatures and flows in each loop make this approach essential.
Loop operations are independent
The operation of pumps and control valves in a secondary circuit has no effect on pressure in other secondary circuits of a primary/secondary system. There is no concern of over-pressuring the control valve seats. In a traditional two-pipe system the pressure on control valves increases as other loop valves close because the reduced flow causes the system pump to shift up on its pump curve. Since closure of a secondary circuit has no impact on other secondary circuits, any circuit can be isolated for service without impacting the rest of the system. Secondary circuit piping and components (pumps and valves) are sized only for the needs of that circuit not for the system as a whole. The flow and head loss through the primary pump never changes and the flow circuit is never interrupted due to closure of control valves. On traditional two-pipe systems, the flow rate changes constantly due to action of the control valves. And a by-pass pressure regulator is needed to protect the pump from high head conditions (dead heading) as branch control valves close. With multiple boilers on secondary loops, there is no flow through idle boilers. So stand-by loss is virtually eliminated. Individual boilers can be isolated for service without affecting the rest of the system.
Simple isolation for service
Piping and pump sizing more efficient No by-pass pressure regulator
Multiple boiler advantages
Disadvantages
The need for a pump in every secondary circuit could be deemed a disadvantage. On the other hand, the individual pumps provide primary/secondary systems with their versatility.
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Part Number 650-000-240/1098
Figure 4 Traditional two-pipe system, typical
Figure 6 Primary/secondary system, typical
By-pass pressure regulator
LOAD
LOAD
Flow/check valves Secondary pump
LOAD
LOAD
Flow/check valves Secondary pump
LOAD LOAD
Control valves Balancing valves
Flow/check valves
Secondary pump
Pump
Primary pump
Fill Expansion tank
Fill Expansion tank
Secondary pump
BOILER
BOILER
Flow/check valves
Figure 5 Two-pipe system load branch

Supply manifold Return manifold
Figure 7 Primary/secondary branch loop

Common piping
Primary piping
Primary piping
LOAD
Balancing valve Control valve
Secondary piping
LOAD
Part Number 650-000-240/1098
11
III
Primary/secondary piping tips
Primary/secondary piping - continued

See Figure 8 for guidelines for the piping connections used in primary/secondary systems. See Figure 13 for placement of the pump relative to an air separator. Common piping (piping between secondary circuit tees)

Common piping must be sized for the larger of the primary or secondary piping. Continue this pipe size at least 8 pipe diameters upstream of the first secondary circuit tee. 4 pipe diameters downstream of the second tee.
Secondary loop tees

Size the secondary circuit tees for whichever flow is larger the primary or the secondary circuit. Space secondary circuit tees no wider than 4 common piping pipe diameters. The tees must be spaced closely to minimize the pressure difference caused by flow through the primary circuit. This pressure difference, if too large, would induce flow in the branch. Secondary pump should flow into secondary circuit (away from primary piping) to raise pressure in the secondary circuit when pump comes on. Thoroughly ream copper piping between tees to prevent causing a pressure drop or turbulence due to burrs.
Preventing gravity flow
Where secondary loop piping is above the secondary circuit tees, use two flow/check valves (Figure 9) or one flow check on the supply and a minimum 18 inch thermal trap on the return (Figure 10). Note you can use a swing check valve in place of the flow/check valve on the return piping if piped horizontally. Where secondary circuit piping is below the branch tees at least 18 inches, no traps or check valves are needed (Figure 11). With an injection mixing circuit piped below the primary piping at least 18 inches, as in Figure 12, no additional thermal trapping or flow/check valves are required, provided the injection pump is turned off when connected branches are satisfied. Do not install flow/ checks in injection risers. Boiler loop piping (for boiler piped on a secondary loop) no flow/check valves are needed if primary piping is below the boiler(s). Otherwise, use a flow/check valve on the supply line. Indirect water heaters refer to Figure 14. Use a flow/check valve in the piping when the water heater is located below the primary. This will prevent gravity flow caused when the water heater water is hotter than the primary loop.
Circuit sequencing
When possible, sequence the secondary circuits off of the primary with the circuits requiring the hottest water first and those requiring the coolest water last. This will reduce the flow rate required in the primary circuit.
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Part Number 650-000-240/1098
Figure 8 Primary/secondary piping definitions

Nearest component or fitting
To secondary circuit
Nearest component or fitting 4 pipe diameters minimum
8 pipe diameters minimum
Common piping
Primary circuit
Primary circuit
Secondary circuit tees
Figure 9 Use two flow/check valves when branch piping
Figure 10 Alternate use a flow/check valve in the branch supply line and a thermal trap below the primary as below.
LOAD
Flow/check valve Secondary pump Flow/check or swing check valve
Flow/check valve
LOAD
Secondary pump
18" Min
Part Number 650-000-240/1098
13
III
Primary/secondary piping - continued

Figure 11 No flow/check valves or thermal traps are needed when branch piping is below the primary. Figure 12 No flow/check valves are needed when injection pump piping is installed below the primary as below.
LOAD
18 min
2 to 4 pipe diameters Primary
Secondary pump
Balancing valve Injection pump Secondary pump
Primary
18" Min
LOAD
Figure 13 Provide minimum 8 pipe diameters between air separator and pump inlet connection as shown below.
8 pipe diameters minimum
Figure 14 Use a flow/check valve in the return line when an indirect water heater is piped below the primary piping to prevent gravity circulation.
Air separator
Fill
Pump
flow/check valve
Indirect water heater
14
Part Number 650-000-240/1098
IV
Combining spaces for zoning
Zoning radiant heating systems

A zone is defined as a heating circuit or group of heating circuits controlled by a common thermostat (or other temperature sensing/regulating method). Radiant heat zoning is similar to other hydronic systems, but the versatility of radiant tubing applications introduces the need for different supply temperatures to spaces and different spaces may have very different needs.
When combining spaces for a zone, make sure they are similar with respect to
t The type of radiant heat application in the space must be similar
Slab on grade, thin slab, below floor, above floor, etc. dont mix system types on the same zone. Below floor applications usually require higher water temperature than other types. The mass of a slab system responds differently from a low mass suspended floor system (above floor or below floor tubing installation). Select radiant circuits requiring similar water temperatures when combining in common zones. Availabe floor area will affect the supply temperature required. So floor area available in spaces must be considered when combining on a zone. Kitchens, sun rooms and rooms with large window areas have different needs from family rooms, bathrooms and bedrooms, for example. Entry areas will have different responses because of the influx of cold air as doors are opened. Carpet acts as an insulator, requiring higher water temperature to the tubing. Tile, on the other hand, is a heat conductor and requires lower supply water temperature. Both have different needs from wood or linoleum. Bedrooms should be zoned separately from high usage living areas, for example.
t Supply water temperatures required must be similar

t Internal and solar gain variations should be similar

t Finished flooring (tile, carpet, wood, etc.) should have similar R-values
t Usage patterns should be similar
Using zone valves and/or valve actuators
Zone valves or valve actuators allow independent operation of zones. This provides a smarter, more adaptive system. Even the best designed radiant heating system may cause uncomfortable space conditions if the space thermostat can't regulate the heat input to the space. With AlumiPex nickel-plated brass manifolds, optional valve actuators (2-wire or 4-wire) are available. Use zone valves or valve actuators whenever possible, with the exception of some constant circulation applications. Some zones of constant circulation systems should never have the flow stopped for example, zones heating warehouse spaces adjacent to loading dock doors. (Keep the water moving in these zones to reduce the potential for freeze-up should the heating source be off while the loading doors are opened.) When using constant circulation with zone valves or valve actuators, install a by-pass pressure regulator in the piping to provide a water path should all zones close for a time (see Figure 65). This will protect the circulator from cavitation caused by high head/low flow operation. Use 4-wire valve actuators to allow the actuators to signal the heating system of the need for heat. For spaces with multiple tubing circuits, use one "master" 4-wire valve actuator on one of the circuits, with 2-wire zone valve actuators on the remaining circuits (as shown in the examples at the end of this Guide). Try to combine small zones as slave zones to larger ones to prevent a small zone from being the only heat zone during a call for heat to the boiler. (Using a buffer tank will also help to reduce cycling of the boiler during light loads.)
Part Number 650-000-240/1098
15
IV
Combining circuits on manifolds
Zoning . . .
continued
When combining radiant circuits on manifolds, make sure the supply temperature requirements of the connected circuits are similar (maximum 10 F difference in design temperature). If circuit lengths vary by more than 10% from one another, provide means for flow balancing, preferably AlumiPex Manifolds with integral valves plus AlumiPex Flow Indicators. Suggestions for combining circuits at manifolds
t Combined flow rate of all connected circuits on any manifold no greater than
12 gpm.
t Maximum difference between design supply temperature in any two circuits

is 10 F.
t Locate manifolds centrally to the heated spaces to reduce leader lengths. t Limit leader length to approximately 50 feet, using multiple manifolds in
different locations if necessary to accomplish this.
t Use a zone valve (or valve actuator) on each circuit to allow adaptive control.
See Figures 16 and 17 for typical uses of zone valves and valve actuators. These diagrams also show the use of multiple manifolds either where needed because of the zone size or because multiple temperatures (differing by more than 10 F) are required on the same or multiple zones.
t When using zone valves with constant circulation systems, install by-pass
pressure regulator between manifold supply and return to provide a flow path for the circulator when all zone valves are closed.
Control circuit transformer sizing
Ensure that the control circuit transformer is large enough for the connected zone valves (or valve actuators) and controls. The rule of thumb is to allow 10 va plus 6 va for each connected AlumiPex manifold valve actuator. See Figure 15, below, for suggested sizing. Be sure to add capacity for controls not considered below, such as other types of zone valves. The AlumiPex manifold valve actuator is available ONLY with a 24 VAC coil. Figure 15 Suggested control circuit transformer sizing when using AlumiPex manifold valve actuators
Number of AlumiPex Valve actuators 1 2 to 3 4 to 5 6 7 to 8 9 to 11 12 to 15
Transformer 24 vac Minimum va 20 30 40 50 60 75 100
16
Part Number 650-000-240/1098
Figure 16 Zoning components manifolds, operators, actuators and zone valves
AlumiPex manifolds without integral valves

Available with 2, 3 or 4 take-offs. Can be joined together for up to 8 take-offs. Use these manifolds only when the lengths of all connected loops are within 10% of one another. If loops differ in length more than 10%, use only manifolds with integral valves to allow flow balancing. Shown with optional purge valves & air vents. Always connect supply end of circuit to bottom manifold. Always connect return end of circuit to top manifold.
AlumiPex manifolds with integral valves

Integral valves can be used with manual operators (shown, standard) or electric valve actuators. Valves have adjustable stops, used to set pressure drop for flow balancing. Available with 2, 3 or 4 take-offs. Can be joined together for up to 8 take-offs. Shown with optional purge valves & air vents. Shown with optional flow indicators recommended to simplify balancing. Always connect supply end of circuit to bottom manifold. Always connect return end of circuit to top manifold.
AlumiPex manifolds , operators & actuators

Use electric actuators for individual flow control on each attached tubing loop. When using multiple actuators on the same zone, use only one 4-wire actuator per zone. Use 2-wire actuators for the remaining loops only one end-switch signal is needed per zone.
Manual operator (standard)
4-wire actuator
2-wire actuator
Zone valves (typical)

Any zone valve may be used where shown. When using 3-wire zone valves, pay special attention to connections to avoid damaging controls due to stray voltages.
Part Number 650-000-240/1098
17
IV
Figure 17a
Zoning . . .
continued
Manifolds supplying a single zone flow control methods

Thermostat
t One zone per manifold t One or more tubing loops per zone t Loop lengths uniform within 10% Use a manifold without integral valves. Tubing loop lengths should be similar; i.e., lengths should not vary more than 10% otherwise, use a manifold with integral valves to allow flow balancing. Use a zone valve to regulate flow, as shown.
Return
Zone valve Supply End switch wiring (to boiler, IPC, etc.)
t One zone per manifold t One or more tubing loops per zone t Loop lengths vary more than 10% Use manifolds with integral valves. Tubing lengths vary more than 10%, so the integral valves are needed to allow flow balancing. The optional flow indicators shown are recommended because they simplify balancing and reduce time required.
Thermostat
Return
Zone valve Supply End switch wiring (to boiler, IPC, etc.)
t t t t
Multiple rooms per zone Multiple temperatures needed One or more tubing loops per manifold Loop lengths uniform within 10%

Thermostat
Return
Return
Use manifolds without integral valves. If design supply temperature for connected loops varies more than 5F, provide separate manifold(s) as needed. Tubing loop lengths should be similar; i.e., lengths should not vary more than 10% otherwise, use a manifold with integral valves to allow flow balancing. Use flow indicators to simplify balancing and reduce time required.
Zone valve Supply Supply End switch wiring (to boiler, IPC, etc.)
Zone valve
Temp 1
Temp 2
t t t t
Multiple rooms per zone Multiple temperatures needed One or more tubing loops per manifold Loop lengths vary more 10%
Thermostat
Return
Return
Same as above, except use manifolds with integral valves to allow balancing flow. Use flow indicators to simplify balancing and reduce time required.
Zone valve Supply Supply End switch wiring (to boiler, IPC, etc.)
Zone valve
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Part Number 650-000-240/1098
Figure 17b Manifolds supplying multiple zones flow control methods
t Multiple zones per manifold t One or more tubing loops per zone

End switch wiring (to boiler, IPC, etc.)
Thermostat Zone 1
Thermostat Zone 2
Use a manifold with integral valves. Provide a 4-wire actuator for each zone plus 2-wire actuators as needed for additional loops on the same zone. If tubing loop lengths in a zone differ by more than 10%, provide flow indicators to simplify balancing and reduce time required.
4-wire actuator
RETURN
Return
2-wire actuator
SUPPLY
Zone 1
Supply Zone 2
t t t t
Multiple rooms per zone Multiple temperatures needed One or more tubing loops per zone Loop lengths vary more than 10%

End switch wiring (to boiler, IPC, etc.)
Thermostat Zone 1
Thermostat Zone 2
Use manifolds with integral valves. If design supply temperature for connected loops varies more than 5F, provide separate manifold(s) as needed. Provide a 4-wire actuator for each zone plus 2-wire actuators as needed for additional loops on the same zone. If tubing loop lengths in a zone differ by more than 10%, use manifolds with integral valves and provide flow indicators to simplify balancing and reduce time required.
4-wire actuator
RETURN RETURN
Return
2-wire actuator
Return
Zone valve
SUPPLY
Zone 1
SUPPLY
Supply Zone 2 Temperature A
Supply
Temperature B
Alternate arrangement for loop lengths all within 10% of one another
RETURN
Return
Zone valve
SUPPLY
Supply
Temperature B
Part Number 650-000-240/1098
19
V
Outdoor reset
Control strategies - general

The purpose of a heating system is to match the heat input to each space to the heat lost from that space. But the design point for a heating system is based on maximum load conditions, to assure adequate heat for the coldest days of the heating season. Consequently, the heating system components are often oversized for the majority of the heating season. When it is warmer outside than design conditions, water supplied to the radiant tubing at the design temperature will cause the heat input to exceed the heat loss. This causes cyclic operation of the heating system, resulting in increased swings in room temperature and wasted heat. Outdoor reset means the temperature of the supply water to the system is adjusted based on the outdoor temperature. As the outdoor temperature rises above the design point, the supply water temperature to the system is reduced. Heat input to the radiant floor or panels is directly related to water supply temperature. So reducing the supply water temperature allows matching heat supplied to heat needed. The Weil-McLain IPC Injection Pump Control provides outdoor reset capability as well as adjustments in reset ratio and outdoor reference temperature, allowing fine tuning of your heating system. See the discussion following.
Figure 18 Typical outdoor reset curves Notice that supply water temperature drops as outdoor temperature rises. Outdoor reference temperature is usually 70 F, but can be changed on the IPC Injection Pump Control if needed. Supply water temperature will equal the outdoor temperature when the outdoor temperature reaches the reference temperature. This is the point at which there is zero heat loss, so no heat will be added to the space. The reset ratio is the change in supply water temperature for each degree change in outdoor temperature. To calculate the right ratio, determine the supply temperature needed at the ODT (outdoor design temperature) for the location. For a 70F outdoor reference, the ratio is: R = (Supply temp -70)/(70-ODT).
190
R=
Supply temp 70 70 - ODT
R=1.5
(1.5 to 1 Ratio)
Supply water temperature
160
where 70 = Outdoor reference temperature (point of no heat requirement) ODT = Outdoor design temperature for the location Supply temp = water supply temperature needed at outdoor design temperature
R=1
(1 to 1 Ratio)
130
R=0.67
(1 to 1.5 Ratio)
100
70 70 50 30 10 -10
Outdoor temperature
Part Number 650-000-240/1098
20
Advantages of outdoor reset

Fewer cycles of the heating components (boiler, zone controls and pumps). Smaller changes in room temperature. Floors will feel more comfortable because floor temperature variations will be smaller. Reduced thermal stressing of wood flooring over heated slabs. Wood is less prone to cupping or cracking when undergoing gradual temperature changes. Reduced expansion noise in distribution piping. Reduced heat loss from distribution piping because of lower supply temperature. From 10% to 15% reduction in fuel usage due to reduced cycling and lower distribution temperature. Can also be used effectively with baseboard and panel radiation.
Advantages of fixed temperature control

Faster warm-up from cold start conditions in mild weather. Faster reaction to sudden influx of cold air into the space. Fewer control adjustments required. Can be done with relatively low cost three-way or two-way temperature regulating valves (provided the boiler return piping protects the boiler from condensation and thermal shock).
Constant circulation
Constant operation of the distribution circulator throughout the system reduces temperature swings in the floor and the heated space. Consider using constant circulation for wood floor applications because it will reduce thermal stressing of wood flooring. Use constant circulation on zones supplying heat to warehouse areas adjacent to load dock doors. With constant circulation in the tubing, the possibility of freeze-up is reduced, even for times when the door is open and the boiler is off. This is because the circulating water can take stored heat from other floor areas to replace the high heat loss near the door.
A note on application of constant circulation

Since zone valves are generally not used on constant circulation systems, all zones must have similar requirements; i.e., if some zones have significant solar gain, these zones may be overheated in a constant circulation system. If you plan to use constant circulation on such systems, provide zone valves to segment the system and a by-pass pressure regulator to protect the pump from running with no flow should all zone valves close at the same time.
Summary
In general, the best performance for the radiant system will come from using outdoor reset with zone valves on each zone. With the outdoor reset control correctly adjusted, and flow rates and supply temperatures for each zone set properly, it will probably not be necessary to set the circulator for constant operation because the matching of heat input to heat loss will keep the circulator on most of the time anyway.
Part Number 650-000-240/1098
21
VI
Injection mixing components

Refer to inside of cover for installation default values
Outdoor Temp Shutoff
Reset On Continuous System Pump Zone Control Input
Power
123
Call For Heat Min Boiler Return Temp
140 F
F O R R E S E T O N L Y
Reset Off
Indoor Sensor Input On/Off System Pump
140 F
System Pump
Boiler
85 F 185 F Supply Temp.
85 F 185 F Max. Supply Temp. 1 2 3 0.2 3.6 Supply Temp Ratio 70 F
90% 70% Injection Pump 50% Speed 30% 10%

Press to Test Lamps & Pump Controls
Power: 120 V 50/60 Hz 1500 VA Inj. Pump: 120 V (ac) 2.4 A 1/5 hp. fuse T2.5 A 250 V Sys. Pump 120 V (ac) 10 A 1/3 hp. pilot duty 240 VA T-stat: 24 to 120 V (ac) 2 VA BLR Relay: 120 V (ac) 5 A 1/6 hp.
The Weil-McLain IPC Injection Pump Control is microprocessorbased, and is designed to control temperatures (system supply and boiler return) by providing variable speed output to an injection pump.
NRTL/C LR 58223
Made in Canada
40 F 100 F Outdoor Temp System Shutoff
120 V (ac) Power N L
Injection System Pump Pump N L N L
RESET INPUTS
Zone or Outdoor Indoor Sensor
REQUIRED SENSORS
Boiler Radiant Signal wiring Return Supply must be rated
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
The IPC can either maintain a fixed radiant supply temperature - Fixed Temperature system - or can vary the radiant supply temperature based on outdoor temperature Outdoor Reset system. The IPC control logic provides PID control/ response methodology; i.e., the control regulates its reaction to a temperature change based on how fast as well as how much the system responds.
POWER 120 VAC Supply temp Call for heat (24 vac or 120 vac signal not used when indoor sensor is installed)
The IPC also provides 120 VAC for an on/off heating system pump. For added flexibility, the control can interface with a zone controller or accept the inputs from an indoor temperature sensor.
Injection pump
System pump
Boiler return temp
Zone control
OR
Indoor sensor
Outdoor sensor
Boiler
Figure 19 Weil-McLain IPC Injection Pump Control
22
Part Number 650-000-240/1098
IPC Adjusting the outdoor reset operation heating line

When the IPC is operated in reset mode, the heating line can be adjusted to match the specific requirements of the distribution system. Two adjustments are used to set the heating line. The dial labeled Outdoor Temp System Shutoff sets the starting point of the heating line (shown as 70 F in Figure 18). The dial labeled Supply Temperature Ratio sets the reset ratio - the slope of the heating line. These two adjustments are independent of each other. Used together they allow a wide range of adjustment to the heating line. When the IPC is used without an indoor sensor it continually calculates the desired supply water temperature based on the following formula in combination with its dial settings: Tsupply = Tstarting + (reset ratio) x (Tstarting Toutside)
where: Tstarting = Outdoor Temp System Shutoff dial setting reset ratio = Supply Temperature Ratio dial setting
Using an indoor sensor with the IPC

The IPC can use an indoor sensor (connected to terminals 7 and 8) in lieu of a powered heat demand signal (24 or 120 vac at terminals 15 and 16). An indoor sensor provides a proportional signal to the IPC, telling it exactly what the room temperature is. This allows the IPC to sense small changes in room air temperature and to initiate minor corrective actions before the room overheats or cools off. The indoor sensor causes automatic adjustment of the heating line because the IPC detects changes in room air temperature and adjusts heating accordingly. Set the desired indoor temperature on the dial labelled Outdoor Temp System Shutoff when using an indoor sensor.
Single and multiple zones using indoor sensors

The indoor sensor provides a single room temperature feedback to the IPC. Thus, it provides single zone control. This is suitable for buildings with "open" floor plans that do not experience widely varying internal heat gains in different parts of the heated space. If multiple independent heating zones are needed, the IPC can be interfaced with several zone controls (such as the tekmar #367 and #368 controls). A zone control receives a signal from a room sensor in each zone, then processes the information to provide feedback to the IPC.
Adjusting the starting point of the heating line is sometimes referred to as parallel shifting the line. Figure 20 shows the results of shifting a typical heating curve. Figure 20 Heating curve changes with changes in starting point temperature
Supply water temperature
80, 80
70, 70
F 80 0, f8 to oin F gp 0 tin ,7 tar 70 s f or to ef oin urv F gp C 60 rtin 0, sta f6 o for int rve po Cu ng rti sta for rve Cu
Reset ratio
Reset ratio is the slope of the heating line. The heating line shifts with the starting point temperature.
Starting point
Starting temp shifts along this line when being adjusted.
60, 60
Outdoor temperature
Part Number 650-000-240/1098
23
VI
IPP panels
Injection mixing components continued

The Weil-McLain IPP Injection Pump Panel simplifies radiant system design and installation. The IPP protects against low return temperatures at the boiler while providing the radiant system the proper supply temperature. This is accomplished by varying the speed of an injection pump while monitoring both the system supply and boiler return temperatures. Both pumps are pre-piped, simplifying installation.
Reliability
Long term protection - Boiler return water protection is fixed by the IPC, unlike manual by-pass arrangements,
which can be defeated by incorrect adjustment of balancing valves. Manual by-pass systems cannot be applied effectively when outdoor reset is desired.
IPP components
The heart of the IPP is the Weil-McLain IPC Injection Pump Control. (This control can be also be used to control a field-supplied injection pump and heating system pump.) Included with the IPP are sensors for heating system water, boiler return water and outdoor temperature. The IPP-150 is factory packaged with both the injection pump, 1, and the heating system pump, 2, pre-piped and pre-wired on the common panel. Also included is a memory stop set manual balancing valve used to adjust the pressure drop in the injection pump circuit, thus providing accurate control even at low injection flow rates.
Energy efficiency
The IPC, combined with injection mixing, allows water supply temperature regulation to be "matched" to radiant heating system response by adjusting the settings of the reset ratio and starting temperature. This pays off in reduced energy usage because room temperature swings will be reduced - particularly when compared to fixed temperature control provided by most mixing valve systems. Using the indoor sensor or zone control option could also reduce heating energy usage due to the improved responsiveness to room temperature. Injection mixing does not introduce a head loss in the primary or distribution circuits, whereas a mixing valve
IPP advantages
When evaluating alternatives for temperature regulation in radiant heating systems, consider the advantages of the IPC Injection Pump Control and IPP Injection Pump Panel
Simplicity
will cause a noticeable head loss, often requiring larger pumps.
Versatility
No additional components are needed to assure
temperature regulation for the radiant heating circuit as well as the boiler return water. The IPP includes the secondary (heating) circuit pump as well as the operating control and the injection pump.
The IPC provides outdoor reset capability (more difficult and costly to accomplish when using mixing valves). To obtain outdoor reset with mixing valves, motorized valves must be used. In addition, an outdoor reset controller or electronic control must be added. The IPC allows future modifications, such as changing to zone control or indoor temperature sensors when system performance indicates the need.
24
Part Number 650-000-240/1098
Figure 21 Weil-McLain IPP-150 Injection Pump Panel
Part Number 650-000-240/1098
25
VII
Determining flow rates

Primary circuit flow rate
Use a flow rate in the primary circuit that will: Rule 1 Provide no lower than 140 F water returning to the boiler. Provide the minimum required water temperature to each secondary circuit. Pay close attention to the minimum
temperature needed at the injection pump for variable speed injection systems. See
first secondary circuit and at least 20 F higher than highest of any other required secondary supply temperature.
Step 2 - Consider Rule 1.
Rule 2
Table 2 in this Guide for the minimum temperature needed at the IPP-150 Injection Pump Panel, based on Btuh load and radiant circuit return water temperature. To calculate a flow rate when you know the temperature drop and heat load Equation 1 Flow rate, GPM = Btuh / (K1 x DT)
where DT is the temperature drop K1 = 494 for water; 449 for 50/50 glycol/water
Use Equation 1 or Table 1 to find the minimum flow rate that will ensure return water to the boiler at no less than 140 F. The Btuh value is the total of all secondary heating loads. Determine maximum temperature drop DT = Supply temperature - 140 F Select K1 (494 for water; 449 for 50/50 glycol) Calculate minimum flow rate from Equation 1 Minimum flow rate = Btuh/(K1 x DT); or use Table 1 to select the minimum flow for this temperature drop. The primary loop flow rate must be no less than this value. A lower flow rate would cause a greater temperature drop, and the return water to the boiler could be low enough to cause condensation or thermal shock.
Step 3 - Consider Rule 2.
Alternatively, use Table 1 in place of Equation 1.
If you know the flow rate and want to find the temperature drop (or rise) Equation 2 DT = Btuh/(Flow rate x K1)
where DT is the temperature drop K1 = 494 for water; 449 for 50/50 glycol/water Flow rate is in GPM
Procedure for determining primary flow rate
Step 1 Estimate minimum primary loop supply temperature.
For an initial estimate, assume a supply temperature no lower than the temperature required at the
Find a flow rate which will ensure each secondary circuit the minimum supply water temperature needed. Assume a trial flow rate equal to the minimum flow rate determined in Step 2. Calculate the temperature drop caused by the first secondary circuit using the assumed flow rate in Equation 2. Subtract this temperature drop from the primary loop supply temperature to determine the supply temperature available to the next secondary circuit. Then calculate the temperature drop caused by this secondary circuit and subtract the number from the primary loop temperature to determine the temperature available to the third secondary circuit. Repeat this process for the entire system to verify that each secondary circuit will receive the minimum required water temperature. If the assumed flow rate results in one or more secondary circuits not receiving adequate supply water temperature, increase the initial primary supply temperature or increase the flow rate, or both, until the selected flow rate and temperature satisfy both Rule 1 and Rule 2.
Part Number 650-000-240/1098
26
Table 1 Minimum water only (not glycol) flow rates use this table to find the minimum flow rate required for a given maximum temperature drop, F
Minimum GPM required for temperature drop ( F) of no more than Btuh

2,000 4,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 60,000 75,000 90,000
2
2.0 4.0 5.1 10.1 15.2
4
1.0 2.0 2.5 5.1 7.6
6
0.7 1.3 1.7 3.4 5.1 6.7 8.4
8
0.5 1.0 1.3 2.5 3.8 5.1 6.3 7.6 8.9
10
0.4 0.8 1.0 2.0 3.0 4.0 5.1 6.1 7.1 8.1 9.1
15
0.3 0.5 0.7 1.3 2.0 2.7 3.4 4.0 4.7 5.4 6.1 6.7 8.1
20
0.2 0.4 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.6 5.1 6.1 7.6 9.1
25
0.2 0.3 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.9 6.1 7.3 8.1
30
0.1 0.3 0.3 0.7 1.0 1.3 1.7 2.0 2.4 2.7 3.0 3.4 4.0 5.1 6.1 6.7 8.4
40
0.1 0.2 0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.5 3.0 3.8 4.6 5.1 6.3 7.6
50
0.1 0.2 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.4 3.0 3.6 4.0 5.1 6.1 8.1
60
0.1 0.1 0.2 0.3 0.5 0.7 0.8 1.0 1.2 1.3 1.5 1.7 2.0 2.5 3.0 3.4 4.2 5.1 6.7 8.4
70
0.1 0.1 0.1 0.3 0.4 0.6 0.7 0.9 1.0 1.2 1.3 1.4 1.7 2.2 2.6 2.9 3.6 4.3 5.8 7.2
80
0.1 0.1 0.1 0.3 0.4 0.5 0.6 0.8 0.9 1.0 1.1 1.3 1.5 1.9 2.3 2.5 3.2 3.8 5.1 6.3
90
0.0 0.1 0.1 0.2 0.3 0.4 0.6 0.7 0.8 0.9 1.0 1.1 1.3 1.7 2.0 2.2 2.8 3.4 4.5 5.6
100
0.0 0.1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.5 1.8 2.0 2.5 3.0 4.0 5.1
20.2 10.1 25.3 12.7
30.4 15.2 10.1 35.4 17.7 11.8
40.5 20.2 13.5 10.1 45.5 22.8 15.2 11.4
50.6 25.3 16.9 12.7 10.1 60.7 30.4 20.2 15.2 12.1
75.9 38.0 25.3 19.0 15.2 10.1 91.1 45.5 30.4 22.8 18.2 12.1
100,000 101.2 50.6 33.7 25.3 20.2 13.5 10.1
125,000 126.5 63.3 42.2 31.6 25.3 16.9 12.7 10.1
150,000 151.8 75.9 50.6 38.0 30.4 20.2 15.2 12.1 10.1
200,000 202.4 101.2 67.5 50.6 40.5 27.0 20.2 16.2 13.5 10.1
250,000 253.0 126.5 84.3 63.3 50.6 33.7 25.3 20.2 16.9 12.7 10.1
TIP
If the required Btuh is not listed in the table, you can add multiples together. For example 300,000 Btuh is 50,000 plus 250,000 so you could add the flow rate for 50,000 to the flow rate for 250,000 to determine the flow for 300,000 Btuh.
Part Number 650-000-240/1098
27
VII
Primary circuit flow rate calculation example, Figure 22
Determining flow rates - continued

Example system, Figure 22 Primary circuit feeds three branch circuits Circuit 1 Domestic water 25,000 Btuh, requires supply water at 180 F minimum. Circuit 2 Baseboard heating circuit 40,000 Btuh, require supply water at 180 F minimum. Circuit 3 Radiant heating circuit 35,000 Btuh, requires supply water at 140 F. Determine the example system flow rate and primary loop supply temperature, T1
Step 1
Secondary circuit 1 requires 180 F, so the primary loop supply temperature must be at least 180 F. Secondary circuit 2 requires 180 F, the highest of the remaining circuits. Add 20 F to this for an initial estimate of the primary loop supply temperature, T1, of 200 F . Determine the temperature drop in the primary loop if the water returns to the boiler at the minimum allowable temperature of 130 F DT = 200 F - 130 F = 70 F. Total heating load, all branches = 25,000 + 40,000 + 35,000 = 100,000 Btuh Determine minimum flow rate from Equation 1 Minimum flow rate = 100,000/(494 x 70) = 2.89 GPM (or 2.9 GPM if taken from Table 1.) The primary loop flow rate must be at least 2.89 GPM to satisfy Rule 1. Assume a flow of 2.89 GPM (from Step 2). Temperature drop due to Branch 1 DT = 25,000/(494 x 2.89) = 17.5 F. T2 = T1 - 17.5 F = 200 F - 17.5 F = 182.5 F. This exceeds the minimum required temperature at branch 2 of 180 F, so the flow rate is acceptable for branches 1 and 2. Continue checking for branch 3. Calculate the temperature drop caused by branch 2 DT = 40,000/(494 x 2.89) = 28.0 F. T3 = T2 - 28 F = 185 F - 28 F = 157 F. This exceeds the minimum temperature required by branch 3, so the flow rate of 3.37 GPM is acceptable for all three branches. Provide a flow rate in the primary circuit of at least 2.89 GPM. Provide a supply water temperature of at least 200 F. Note that, if the load in branch circuit 1 had been 60,000 Btuh, for example, the flow rate of 2.89 GPM would not have been high enough to provide branch circuit 2 with water at 180 F. The temperature drop due to branch 1 would have been 60,000/(494 x 2.89) = 42 F. And the supply temperature, T2, to branch 2 would have been 200 F - 42 F = 158 F. To find the necessary flow rate the maximum allowable temperature drop due to branch 1 is 20 F in order to provide 180 F to branch 2. (Because DT = 200 F - 180 F = 20 F.) So, from equation 1, the minimum flow rate would be 60,000/(494 x 20) = 6.07 GPM. (This would be 6.1 GPM if taken from Table 1.)
Part Number 650-000-240/1098
Step 2
Step 3
Selection
Comments - extended example
28
Figure 22 Primary circuit flow rate example
LOAD
40,000 Btuh
Secondary pump
2
Flow/check valves
LOAD
25,000 Btuh
Secondary pump
LOAD
35,000 Btuh
1
Flow/check valves
Secondary pump
3
Flow/check valves
180 F min
180 F min
140 F min
T1
T2
T3
T4
Primary pump Expansion tank
Fill
130 F min
Secondary pump
Flow/check valves
Rule 1 T4 no less than 130 F Rule 2 T1, T2 and T3 no less than required at branches 1, 2 and 3, respectively.
Flow/check valves
BOILER
Part Number 650-000-240/1098
29
VII
Injection pump flow rates
Determining flow rates - continued

The injection pump only has to inject enough hot water from the primary loop into the heating circuit loop to raise the heating circuit return temperature to the desired supply temperature. The formula for the injection pump flow rate when you know the heating load (Btuh), the heating circuit return temperature (TR), and the temperature of the water supplied to the injection circuit, (TS) is Equation 3 Injection flow, GPM = Btuh / [(TS - TR) x K1]
where DT is the temperature drop and K1 is taken from the following table
Fluid temperature 100 F 140 F 180 F
K1 Water only 494 491 486
K1 30% glycol 478 479 479
K1 50% glycol 449 453 454
When applying an IPP-150 Injection Pump Panel, ensure that the supply water temperature available at the panel will be no less than the temperatures given in Table 2 If the supply temperature is lower than the number shown, the panel will not be able to deliver enough hot water to the radiant circuit to achieve the heat load required. (Table 2 is based on a full load flow rate in the
injection riser of 4.5 GPM.)
Injection pump flow rate example

A radiant heating circuit has a load of 50,000 Btuh. The supply temperature reaching the injection pump will be 160 F. And the radiant circuit requires water at 100 F, returning at 90 F. Use Equation 3 (with K1 = 495 for 100 F) Injection flow rate = 50,000 / [(160 - 110) x 495] = 2.0 GPM Table 2 Minimum supply water temperature needed at an IPP-150 Injection Pump Panel
Heat Minimum supply temperature to IPP-150 Injection Pump Panel Load with radiant circuit return temperature ( F) of (MBH) 90 100 110 120 130 140 150 160
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 94 99 103 108 112 117 121 126 130 135 139 144 148 153 157 104 109 113 118 122 127 131 136 140 145 149 154 158 163 167 114 119 123 128 132 137 141 146 150 155 159 164 168 173 177 124 129 133 138 142 147 151 156 160 165 169 174 178 183 187 134 139 143 148 152 157 161 166 170 175 179 184 188 193 197 144 149 153 158 162 167 171 176 180 185 189 194 198 203 207 154 159 163 168 172 177 181 186 190 195 199 204 208 164 169 173 178 182 187 191 196 200 205 209
30
Part Number 650-000-240/1098
Secondary circuit Domestic water circuits flow rates Determine the flow rate for domestic water heating based on the recommended flow rate given by
the water heater manufacturer. Weil-McLain PLUS and GOLD Plus water heater literature includes this information.
Baseboard circuits
The flow rate for baseboard circuits is usually based on a 20 F drop and can be calculated using Equation 1 or read directly from Table 1.
Radiant circuits
Determine the flow rate for the radiant loops using the AlumiPex Radiant Expert computer program or AlumiPex Design Guide (when available). As a rule of thumb, the flow rate per loop will generally be 1 gpm or less for tubing (higher for larger tubing). The radiant circuit pump must deliver water to all of the circuits piped off of the manifold. So the total flow rate required from the pump is the sum of the flows in all connected circuits. The flow rate may also be determined from the desired temperature drop and heat load, using Equation 1 or Table 1. Estimate the total flow for a radiant heating circuit by assuming some typical conditions Temperature drop = 10 F. Fluid in circuit is water (no glycol).
Radiant heating circuit flow rate example

Design conditions
Heat load = 15 Btuh per square foot. Loop length 300 feet of tubing. Tubing layout at 12 inches on center. Water only (no glycol). Temperature drop = 10 F, from 100 F to 90 F.
Determine the estimated heat load for the loop
To determine how many square feet of floor the 300 feet of tubing will cover, consider that, at 12 inch center to center tube spacing, there will be one linear foot of tubing to each square foot of floor space. (For any other tubing spacing, divide 12 by the tube spacing in INCHES to find the number of feet of tubing per square foot of floor. For example, 6 inch tube centers would require two linear feet of tubing per square foot of floor; i.e., 12/6 = 2.) Since there is 1 linear foot of tubing per square foot for this example of 12 inch centers, the 300 foot tubing loop will cover 300 square feet of floor. The loading is 15 Btuh per square foot of floor, so the total load of the loop is 300 feet times 15 Btuh per square foot, or 4,500 Btuh total.
Determine the estimated flow rate
Part Number 650-000-240/1098
Use Equation 1 (or Table 1) Flow rate = 4,500/(495 x 10) = 0.91 GPM.
31
VIII
Determining head loss

Equivalent length
Determine the pipe size for each circuit based on the required flow for that circuit (in GPM), and the desired head loss. Avoid high head losses where possible. High head losses require more energy to pump the water, resulting in higher electrical costs and higher costs for the pumps. You can use the following method to determine head losses in the system, boiler and water heater circuits. The head loss through a length of pipe is directly proportional to its length. For any fitting or valve, there is an equivalent straight length of pipe which would cause the same head loss as the fitting or valve. This length of pipe is the equivalent length for that fitting. See Table 5 for equivalent lengths of copper and threaded fittings. The Total Equivalent Length (TEL) for a circuit is the sum of the length of the piping plus the equivalent lengths of all fittings in the circuit. or steel pipe size, select the corresponding a, b, and c from the table. Use a value of c =1 except where temperature is closer to 100 F or 180 F than to 140 F, where the appropriate value of c from the table may be used to adjust the pressure loss. Calculate the piping circuit head loss, in feet, as: Equation 4 H = (TEL/100) x a x (GPM)b x c
Add to the piping head loss the head losses for boilers, water heaters, baseboard, heat exchangers or any other components of this sort in the circuit. Refer to the instructions or literature on these components for the estimated head loss. TIPS Estimate " baseboard as if it were just a straight length of " pipe. For cast iron boilers estimate a head loss of 1 to 2 feet for residential boilers and 2 to 5 feet for commercial boilers.
The equivalent length depends on pipe size. So begin by estimating the TEL as 1.5 times the length of the piping. In fact, for small systems, this estimate is usually adequate for the head loss calculation. This is because the circuit lengths are relatively simple and short, and the head losses are low. Example: if the circuit contains 130 feet of straight pipe, estimate the TEL as: TEL = 1.5 x 130 = 195 feet.
Head loss (series circuits)

Table 3 provides the means of calculating head losses in piping circuits. It also provides recommended maximum and minimum flow rates for each size AlumiPex or copper tubing, or steel pipe. The maximum is intended to minimize noise and prevent erosion. The minimum is intended to assure adequate movement of air through the system.
If the head loss based on the trial pipe size is acceptable (usually between 5 and 15 feet), check the actual equivalent length of the circuit using the pipe size you selected. Obtain the equivalent lengths of all valves and fittings from Table 5. If the TEL is different from your estimate, use the new, calculated, TEL in the head loss formula, Equation 4. If the result is acceptable, use the required flow and calculated head loss to select a pump. If not, increase (or decrease) the pipe size as indicated and redo the calculation.
Glycol/water systems
For systems filled with propylene glycol/water, first do the calculations as if the system were filled with water only. Then apply the correction factors given in Table 4. You will see from the table that the flow rate for glycol/ water must be from 14% to 16% higher than water only to achieve approximately the same heat transfer. The head loss for any give flow rate will be higher for the glycol/ water mixture than for water only.
Procedure
Select a trial pipe size from Table 3 based on the design flow rate, in GPM, for the circuit. For any given copper
32
Part Number 650-000-240/1098
Table 3 Head loss data and minimum/maximum flow recommendations
AlumiPex tubing - head loss data - water @ 140 F

Size Minimum Flow, GPM 0.55 0.91 1.52 2.56 Maximum Flow, GPM 2.19 3.65 6.07 10.26
c
Pipe ID 0.472 0.610 0.787 1.024 Correction @ 100 F 1.095 1.095 1.095 1.095 Correction @ 180 F 0.930 0.930 0.930 0.930
a
3.9087 1.1507 0.3379 0.0865
b
1.750 1.750 1.750 1.750
Velocity @ Min. fps 1.00 1.00 1.00 1.00
Velocity @ Max. fps 4.00 4.00 4.00 4.00
Copper Tubing, Type M - head loss data - water @ 140 F

Size Minimum Flow, GPM 1.189 2.41 4.09 6.12 8.56 14.82 36.16 58.00 Maximum Flow, GPM 3.17 6.44 10.90 16.32 22.83 39.52 91.08 146.11
c
Correction @ 100 F 1.095 1.095 1.095 1.095 1.095 1.095 1.071 1.071 Correction @ 180 F 0.930 0.930 0.930 0.930 0.930 0.930 0.947 0.947
a
1.588 0.295 0.085 0.0324 0.0146 0.00397 0.00113 0.000478
b
1.750 1.750 1.750 1.750 1.750 1.750 1.812 1.812
Velocity @ Min. fps 1.50 1.50 1.50 1.50 1.50 1.50 2.37 2.67
Velocity @ Max. fps 4.00 4.00 4.00 4.00 4.00 4.00 5.98 6.72
Pipe ID 0.569 0.811 1.055 1.291 1.527 2.009 2.495 2.981
1 1 1 2 2 3
Steel pipe, schedule 40 - head loss data - water @ 140 F

Size Minimum Flow, GPM 1.42 2.49 4.04 6.99 9.52 15.69 34.32 60.57 Maximum Flow, GPM 3.79 6.65 10.77 18.65 25.38 41.83 84.50 149.11
c
Correction @ 100 F 1.087 1.087 1.087 1.087 1.087 1.087 1.053 1.053 Correction @ 180 F 0.936 0.936 0.936 0.936 0.936 0.936 0.960 0.960
a
0.378 0.140 0.0595 0.0225 0.0130 0.00538 0.00105 0.000366
b
1.771 1.771 1.771 1.771 1.771 1.771 1.858 1.858
Velocity @ Min. fps 1.50 1.50 1.50 1.50 1.50 1.50 2.30 2.63
Velocity @ Max. fps 4.00 4.00 4.00 4.00 4.00 4.00 5.66 6.47
Pipe ID 0.622 0.824 1.049 1.380 1.610 2.067 2.469 3.068
1 1 1 2 2 3
Glycol/water correction factors

Average glycol/water temperature 100 140 180 220 F F F F Multiply below times water only flow rate for same heat transfer 1.16 1.15 1.14 1.14 Multiply below times water only head loss for 30% glycol/water 1.24 1.19 1.17 1.15 Multiply below times water only head loss for 50% glycol/water 1.44 1.36 1.31 1.27
Table 4 Correction factors when using 50/50 glycol/water in place of water only
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Table 5
Determining head loss - continued
Equivalent lengths, feet of pipe, for common copper and steel valves and fittings
Copper fitting equivalent lengths Copper size

90 degree elbow 45 degree elbow Tee (straight run) Tee (side port) B&G Monoflo tee Gate valve Globe valve Angle valve Ball valve (standard port) Swing check valve Flow-check valve (B & G) Butterfly valve
1.00 0.50 0.30 2.00 n/a 0.20 15.00 3.10 1.90 2.00 n/a 1.10 2.00 0.75 0.40 3.00 70.00 0.25 20.00 4.70 2.20 3.00 83.00 2.00
1
2.50 1.00 0.45 4.50 23.50 0.30 25.00 5.30 4.30 4.50 54.00 2.70
1
3.00 1.20 0.60 5.50 25.00 0.40 36.00 7.80 7.00 5.50 74.00 2.00
1
4.00 1.50 0.80 7.00 23.00 0.50 46.00 9.40 6.60 6.50 57.00 2.70
2
5.50 2.00 1.00 9.00 23.00 0.70 56.00 12.50 14.00 9.00 177.00 4.50
2
7.00 2.50 0.50 12.00 n/a 1.00
3
9.00 3.50 1.00 15.00 n/a 1.50
4
12.50 5.00 1.00 21.00 n/a 2.00
11.50 n/a 10.00
14.50 n/a 15.50
18.50 n/a 15.00
Threaded fitting equivalent lengths Nominal pipe size

90 degree elbow Long radius 90, & 45 std. elbow Standard tee, through flow Standard tee, branch flow Close return bend Mitre bend Gate valve, full open Globe valve, full open Angle valve, full open Swing check valve, full open Butterfly valve 45 deg. 90 deg. 0.41 17.60 7.78 5.18 0.55 23.30 10.30 6.86 0.70 29.70 13.10 8.74 0.92 39.10 17.30 11.50 1.07 45.60 20.10 13.40
1.55 0.83 1.00 3.10 2.59 2.06 1.10 1.40 4.10 3.43
1
2.62 1.40 1.80 5.30 4.37
1
3.45 1.84 2.30 6.90 5.75
1
4.03 2.15 2.70 8.10 6.71
2
5.17 2.76 3.50 10.30 8.61 2.60 10.30 1.38 58.60 25.80 17.20 7.75
2
6.17 3.29 4.10 12.30 10.30 3.10 12.30 1.65 70.00 30.90 20.60 9.26
3
7.67 4.09 5.10 15.30 12.80 3.80 15.30 2.04 86.90 38.40 25.50 11.50
4
10.10 5.37 6.70 20.10 16.80 5.00 20.10 2.68 114.00 50.30 33.60 15.10
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Part Number 650-000-240/1098
TEL for varying pipe sizes

You must determine the TEL (total equivalent length) for each pipe size, then calculate the head loss for that piping segment. The equivalent length data cannot be combined between pipe sizes.
Determining head losses for circuits in parallel

Flowing liquids will seek the path of least resistance. For parallel branches this means that flow will favor the lower head loss branches. Where the design head losses of parallel branches differ more than 10%, use balancing valves to assure proper flow distribution. The balancing valves are used to increase the head loss in lower loss branches. Ideally, the valves are closed off enough that the head loss in every branch is the same as the branch with the highest design head loss. The required flow for a pump feeding parallel branches is the sum of the design flow rates for each connected branch. The required pump head for a pump feeding parallel branches equals the highest design head loss of any connected branch plus the head loss through the distribution piping . Figure 23 For example, see Figure 23. This simplified circuit has three parallel branches. The design flow and head loss for each branch is given in the figure.
1.5 GPM @ 4.5 feet 2 GPM @ 7.0 feet
(1 or 3) is the same as the pressure drop through branch 2. When the balancing valves are set properly, the head loss across all branches will be approximately 7.0 feet water column. The total flow required of the pump is 5.5 GPM (sum of all three branch design flows). The pump head required of the pump is the sum of the highest branch design head loss plus the head loss in the distribution piping, or 3.0 feet plus 7.0 feet = 10.0 feet.
Flow in parallel circuits
If the balancing valves were not closed down on branches 1 and 3, they would receive higher than their design flows and branch 2 would receive less than design flow because the fluid flow will always seek the path of least resistance. The balancing valves are closed off until the head loss through the branch
Balancing valves
Distribution piping - Head loss = 3.0 feet Flow = 1.5 + 2 + 2 = 5.5 GPM
The branch with the highest design head loss is number 2, where the head loss at design flow of 2 GPM is 7.0 feet water column.
2 GPM @ 5.5 feet
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Head losses for AlumiPex tubing circuits

The majority of the head loss in AlumiPex radiant heating circuits is in the tubing itself. It is not necessary to consider the head loss in the AlumiPex manifolds separately. To determine the head loss in an AlumiPex radiant heating circuit, calculate the head loss in the piping, valves and fittings in the supply and return piping to the manifolds using the methods given in this Guide for piping. Then add the loss in the AlumiPex tubing, using Equation 5. The design head loss used for a group of AlumiPex loops piped off a single manifold assembly must be the highest design head loss for any loop connected to the Table 6 Values of K2 for Equation 5
Fluid Water 30% Glycol 50% Glycol
manifold. The head losses for the other loops must be made equal to this highest head loss by closing down on the manifold valves. This is how the system is balanced. (Glycol data is for propylene glycol/water mixtures in the ratios shown.) Equation 5, Head loss in AlumiPex feet head = K2 x L (feet) x GPM1.75
where L is the total length of tubing in a loop and K2 is a constant from the table 6, below
K2 - Factor for AlumiPex tubing head loss Temp

100 140 180 100 140 180 100 140 180 F F F F F F F F F
Tubing 0.0428 0.0391 0.0364 0.0529 0.0466 0.0492 0.0617 0.0547 0.0650
Tubing 0.0126 0.0115 0.0107 0.0154 0.0137 0.0145 0.0181 0.0161 0.0191
Tubing 0.00370 0.00338 0.00314 0.00455 0.00402 0.00425 0.00533 0.00473 0.00562
1 Tubing 0.000947 0.000865 0.000804 0.001164 0.001030 0.001089 0.001365 0.001211 0.001438
AlumiPex tubing flow rate calculation example, Figure 24

Figure 24 is a typical manifold arrangement with four tubing loops connected. In this example, we will determine the pump and piping required to supply the manifold. (The heating system designer wants a temperature drop of 13 F from 105 F to 92 F.) When possible, do a tubing layout drawing for the building using a computer drafting program for the most accurate means of determining tubing loop length. Use the following method to estimate the required length of tubing when a tubing layout drawing is not available. The heating load for the spaces in the example is 15 Btu per square foot, with tubing to be spaced on 9 inch (0.75 foot) centers. With the tubing at this spacing, there is approximately 1.33 linear feet of tubing per square foot of floor space. Use this to determine the approximate length of tubing needed for each space. Add to the tubing needed for the space the length of tubing required to extend from the supply and return manifolds to the space (called the leader lengths). Then add an additional 5% to provide for variations in actual layout. The floor areas and leader lengths for the loops are: Loop 1 175 square feet of floor space; total leader length needed = 40 feet.
Requires 175 x 1.33 = 233 feet of tubing for space plus 40 feet = 273 feet. Add 5% allowance = 14 feet. Total length of loop = 287 feet.
Loop 2 185 square feet of floor space; total leader length needed = 20 feet.
Loop 3 200 square feet of floor space; total leader length needed = 20 feet.
Loop 4 150 square feet of floor space; total leader length needed = 30 feet
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Part Number 650-000-240/1098
Figure 24 Example AlumiPex manifolds with tubing circuits and pump
287 feet, AlumiPex
Manifold valves Return manifold Supply manifold
279 feet, AlumiPex
300 feet, AlumiPex
242 feet, AlumiPex
TUBING LOOPS
Supply manifold
287 feet AP tubing
279 feet AP tubing
300 feet AP tubing
Manifold valves Return manifold
Distribution piping - 1 copper tubing, type M Total equivalent length = 175 feet
SCHEMATIC DIAGRAM OF TUBING BRANCHES
242 feet AP tubing
Part Number 650-000-240/1098
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VIII
AlumiPex tubing flow rate calculation example, Figure 24, continued

Now determine the flow rate required for each of the loops. The heating system will be filled with water (no glycol). The temperature drop is to be 13 F (from 105 F to 92 F). Calculate the heat load for each loop by multiplying 15 Btuh per square foot by the area (in square feet) heated by the loop. Apply Equation 1 to calculate the flow rate in each loop.
For the example in Figure 24: Loop 1 Loop 2 Loop 3 Loop 4 Total Heat load = 15 x 175 = 2625 Btuh; Flow rate = 2625/(494 x 13) = 0.41 GPM Heat load = 15 x 185 = 2775 Btuh; Flow rate = 2775/(494 x 13) = 0.43 GPM Heat load = 15 x 200 = 3000 Btuh; Flow rate = 3000/(494 x 13) = 0.47 GPM Heat load = 15 x 150 = 2250 Btuh; Flow rate = 2250/(494 x 13) = 0.35 GPM Total flow rate for pump = 0.41 + 0.43 + 0.47 + 0.35 = 1.66 GPM.
Determine the head loss for each AlumiPex tubing loop at design flow rate using Equation 5 (using the K2 value for tubing and 100 F, since the water ranges from 105 F to 92 F). For these conditions, the K2 value is 0.0428. Loop 1 Head loss = .0428 x 287 x 0.411.75 = 2.58 feet Loop 2 Head loss = .0428 x 279 x 0.431.75 = 2.73 feet Loop 3 Head loss = .0428 x 300 x 0.471.75 = 3.43 feet (highest head loss) Loop 4 Head loss = .0428 x 287 x 0.351.75 = 1.96 feet Note that the manifold valves would have to be partially closed on loops 1, 2 and 4 to cause the head losses for these loops to match that of loop 3, the branch with the highest loss.
Determine the pipe size and head loss in the distribution piping. The flow in the distibution piping will be 1.66 GPM. Find a pipe size in Table 3 which is suitable for this flow. The flow is within the range of copper tubing, so select this as the pipe size. The example system has (12) 90-degree elbows (not shown) and (2) gate valves plus 150 linear feet of piping. Find the equivalent lengths of these fittings for copper from Table 5 (1.00 feet per elbow; 0.20 feet per gate valve). The TEL for the distribution piping is TEL = 150 + (12 x 1.00) + (2 x 0.20) = 162 feet. The head loss for the distribution piping using copper tubing, at 1.66 GPM would be (from Table 3) Head loss = (162/100) x 1.588 x 1.661.75 = 6.25 feet.
Determine total required head for the pump The highest loop head loss for any of the AlumiPex loops is 3.43 feet. Add this to the distribution piping loss of 6.25 feet, for a toal head loss of 9.68 feet.
Solution Select a pump capable of 1.66 GPM at a head loss of 9.68 feet.
Note
If the loading required of a tubing loop requires too high a flow rate (or pressure drop), consider increasing the tube diameter, provided the flow rate in the tubing is within the recommended flow rate range (between the minimum and maximum recommended flow rates).
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Part Number 650-000-240/1098
IX
Selecting pumps
Method 1 Calculate flow rate and head loss - select pump from pump curve
The design flow rate and head loss for a circuit are called the design point. Calculate the design point using the procedures given in this guide. Then select a pump whose curve passes close to (preferably slightly above or on the design point). See Figure 25. Figure 26 combines the pump curves for some common Taco, Grundfos and Bell & Gossett pumps. Use Figure 26 or another pump curve to select the pump required. Apply Equation 6 for several flow rates in the desired range. Then draw these points on the pump curve and connect with a line as shown in the pump curve segment in Figure 25, below. The design flow rate for the example circuit is 1.66 GPM and the design head loss is 9.68 feet. The system points used in Figure 25 are: Example The previous example on pages 36 through 38 resulted in a design point of 1.66 GPM at a head loss of 9.68 feet (when using AlumiPex tubing with distribution piping). Find a pump (or pumps) using Figure 26 which could accomplish this design point. The Taco 007 pump could provide 1.7 GPM at a head of approximately 10.5 feet. This is probably an acceptable pump selection. The Taco 0010 pump could provide 1.7 GPM at a head of approximately 11.5 feet. This would probably be an acceptable selection as well. None of the other pump curves passes close to the design point. To determine what each of these selected pumps would actually do on the circuit, draw a system curve on the pump curve. A system curve is a line which represents what the head loss in the system will be as the flow rate changes. Flow rates below the design point will cause lower head losses. Flow rates above the design point will cause higher head losses. The head loss at any flow rate can be estimated from the design point flow rate by Equation 6
Head loss = Design head loss x (Flow rate/Design flow rate)1.75
where Flow rate is the rate at which the head loss is to be estimated Design head loss and Design flow rate are the known Design Point data
1.66 GPM where pressure drop = 9.68 feet (design point) 2 GPM where pressure drop = 9.68 x (2/1.66)1.75 = 13.4 feet 1 GPM where pressure drop = 9.68 x (1/1.66)1.75 = 4.0 feet
The flow rate and head loss for any pump is the point at which the system curve crosses the pump curve. The Taco 007 pump would provide about 1.8 GPM at 10.6 feet. The Taco 0010 pump would provide about 1.9 GPM at 11.5 feet.
Figure 25 Drawing a system curve to determine pump performance
0012
System curve
0010 007
Design point
The system curve will always pass through the design point.
Part Number 650-000-240/1098
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IX
Figure 26
Selecting pumps - continued
Pump curves for some typical residential/light commercial circulators (Taco 007, 0010, 0011, 0012 and 0014; Grundfos 15-42, 26-64 and 43-75; B & G NRF-22, PL-30 and PL-50) See Appendix for pump curve equations.
30
0011
25
Feet head
26-64
20
PL-30
15
43-75
10
0010 007
0012
PL-50
5
15-42 NRF-22
0014
0 0 10 20 30 40 50
Flow rate (gpm)
40
Part Number 650-000-240/1098
Method 2 Calculate flow rate and select pump from quick selector curves
Figures 27 through 30 are quick selector curves for selecting pumps based on a known flow rate and circuit length. The pumps included in these curves are Taco 007, 0010, 0011, 0012, 0014. Grundfos 15-42, 26-64, 43-75. Bell & Gossett NRF-22, PL-30, PL-50. (See Appendix for pump curve equations.) If you can't find a good pump selection, try another pipe size. You can refine and verify your selection by calculating the actual TEL for your circuit using the equivalent length data in this Guide.
Example:
A circuit with 300 linear feet of piping; heating load 200,000 Btuh; using water from 180 F to 160 F. Estimate the TEL at 1.5 times 300, or 450 feet. Using Equation 1, the required flow rate for a 20 F drop would be: Flow rate = 200000/(494 x 20) = 20.2 GPM
Use these curves only when the pipe diameter is the same throughout the circuit being analyzed. This method will work well for determining both pipe size and pump selection for primary circuits and baseboard heating secondary circuits. To select a pump using this method Calculate the required flow rate based on the heating load (Btuh) and the desired temperature drop using Equation 1: GPM = Btuh/(494 x DT). Select a trial pipe size using Table 3 that is, a pipe size for which the flow rate falls between the minimum and maximum recommended. Determine the linear feet of piping expected for the circuit. Multiply this number by 1.5. The result is your approximate TEL (total equivalent length) for the circuit. Select the Figure from Figures 27 through 30 for the pipe size you have selected. Select the pump which can deliver the flow rate and TEL you need.
From Table 3, either 1 or 2 copper pipe would be usable (though the pressure drop would be higher in 1 pipe). Use 1 copper pipe for the trial size. From Figure 30, with 1" copper pipe at a TEL of 450 feet, a Taco 0011 or 0014 would deliver about 19.5 GPM at 450 feet TEL. Or a B & G model PL-50 would deliver about 21.3 GPM. At 19.5 GPM, the temperature drop would be (from Equation 2) 200000/(494 x 19.5) = 20.8 F. So the Taco 0011 or 0014 would probably be an adequate selection.
Note, from Figure 30, that a model 0010, 0011, PL-30 or 26-64 would be the likely choices if the pipe size were increased to 2 copper pipe. These pumps would deliver about 25 GPM. Verify the pump selection by doing a complete calculation of the TEL, using the data in this Guide.
Part Number 650-000-240/1098
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IX

Figure 27 Quick selector pump curves for and AlumiPex tubing
Pump performance, " AlumiPex

2.5
Flow rate, GPM
43-75
2.0
PL-30 0014
1.5
26-64 NRF-22 PL-50 0011 0010 15-42
1.0
0012
0.5
0 100 200 300 400
007
500 600 700 800 900 1000
Circuit equivalent length, feet
Pump performance, " AlumiPex

7
43-75 PL-30 0014
Flow rate, GPM
6 5 4 3 2 1
0 100 200 300 400
26-64 NRF-22 0012 0010 15-42 007 PL-50 0011
500
600
700
800
900
1000
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Part Number 650-000-240/1098
Figure 28 Quick selector pump curves for 1 AlumiPex tubing and copper tubing
Pump performance, 1" AlumiPex

12 11
43-75 PL-30 0014 26-64 NRF-22 0012 0010 15-42 007 PL-50 0011
Flow rate, GPM
10 9 8 7 6 5 4 3
0 100 200 300 400 500
600
700
800
900
1000
Pump performance, " copper tubing

7
Flow rate, GPM
PL-30 007 0014
NRF-22 PL-50
2 100
200
300
400
500
600
700
800
900
1000
Part Number 650-000-240/1098
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IX

Figure 29 Quick selector pump curves for 1 and 1 copper tubing
Pump performance, 1" copper tubing

12
0012
Flow rate, GPM
11 10 9 8 7 6 5 4 100 200 300 400
PL-30 0014 26-64 15-42 NRF-22 PL-50 0011 43-75
0010 007
500
600
700
800
900
1000

18 17
0011 43-75 PL-50
Flow rate, GPM
16 15 14 13 12 11 10 9 8 7 6 100
0014 PL-30 26-64

NRF-22 0010 15-42 0012 007
200 300 400 500 600 700 800 900 1000
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Part Number 650-000-240/1098
Figure 30 Quick selector pump curves for 1 and 2 copper tubing

25 24 23 22 21 20 19 007 18 17 16 15 14 NRF-22 13 12 11 10 9 100 200
0011 43-75 PL-50
Flow rate, GPM
0014 PL-30 26-64
0010 15-42 0012
300
400
500
600
700
800
900
1000

40
Flow rate, GPM
43-75
35
PL-50 0012
30
PL-30 26-64
0014
25
0011 NRF-22
20
0010 15-42 007
15 100
200
300
400
500
600
700
800
900
1000
Part Number 650-000-240/1098
45
Piping radiant circuits

Overview
The following sections provide suggested piping and wiring methods for radiant heating systems and for hybrid systems which provide domestic water and/or baseboard heating as well as radiant heating. The radiant heating circuits illustrated in this Guide are all shown with injection mixing. But you can substitute dual temperature mixing valves for the injection mixing arrangement in all of the examples given. Follow the piping guidelines for dual mixing valve circuits given in previous section II, Piping and control methods, Method 2 - Dual three-way valves.
Higher temperature radiant circuits

The piping (and associated wiring) suggestions shown in the following pages all provide some means of protecting the boiler from cold return water temperatures. The special case of system CP-1 adding a small radiant zone to a baseboard heating system does not provide return water temperature regulation because the radiant zone is too small to cause unusually low return temperatures. Some radiant heating applications operate with temperatures similar to those of finned tube baseboard systems for example, where the tubing is suspended in the joist bay, or for suspended floor applications with the tubing underneath and carpet on the floor. In these cases, the supply temperature at design conditions will often be 160 F or higher. For those suspended floor radiant heating applications requiring at least 160 F supply water, the return water temperatures will be similar to finned tube baseboard applications. Consequently, it would not usually be necessary to provide return water temperature protection for the boiler in such applications. These radiant heating zones can be installed as secondary circuits directly connected to the primary, without using a mixing valve or injection mixing system to protect the boiler.
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Part Number 650-000-240/1098
Pump location
In the following system examples, the primary circuit pump is shown mounted in the supply piping, with the expansion tank and air separator on the inlet side of the pump (with the exception of GV boiler systems). This is the preferred location for all pumps, and the only recommended location for commercial system pumps. Many packaged residential boilers are supplied with the pump on the return line to the boiler. This is acceptable for residential applications and for multiple boiler systems using residential packaged boilers. See the Caution statement below regarding location of the expansion tank and fill connection. Always connect the fill line at the expansion tank. Locate the expansion tank (diaphragm or bladder type) on the inlet side of the pump, even if the pump is mounted on the boiler return line. When using a compression tank (expansion tank in which air is exposed to the water), mount the compression tank and fill connection in the supply piping, regardless of the location of the pump. Failure to follow these guidelines could result in damage to the boiler and system components.
Alternative piping configurations

Most of the examples shown in this Guide utilize Weil-McLain IPP Injection Pump Panels and IPC Injection Pump Controls. You will also find that we have given an alternative piping arrangement for example systems CP-2 through CP-12 in Radiant heating system examples. This Guide does not exclude other engineered systems that protect the system and the boiler (as directed by the boiler manufacturer). We have concentrated on injection mixing and mixing valve piping configurations in order to provide you with as complete an analysis and guide for their applications as possible. Weil-McLain can provide you with supplementary materials for other specific piping alternatives. Also refer to the boiler (heating source) manufacturers instruction manuals and design information for their requirements and specific suggestions.
Part Number 650-000-240/1098
47
Piping radiant circuits - continued

Single supply temperature using injection mixing
The piping examples in this Guide utilize the Weil-McLain IPP Injection Pump Panel. This assures three-temperature control for the system; i.e., protecting the boiler from condensation while controlling system water and space temperatures. For those applications which are too large for the IPP-150, install your own injection pump and use the IPC Injection Pump Control to regulate it. For most of the examples in this Guide, you can use the dual three-way valve option (see Section II) in place of variable speed injection, though the three-way valve method is much less versatile. Whatever piping method you use, it must provide control of the return water temperature to the boiler. AlumiPex manifolds are shown in the example diagrams in this Guide with and without manifold valve actuators. Use actuators when you wish to provide zone control. When using actuators and continuous operation of the pump, install a by-pass pressure regulator across the supply and return connections of the circuit. This will protect the pump from cavitation when the zone valves close off. When all manifolds in a circuit must receive the same temperature water, use the basic piping shown in Figure 31a or Figure 31b. For applications involving multiple manifolds that require different supply temperatures, use the piping shown in Figure 32 or Figure 33, on the following pages.
NOTE: You can substitute dual mixing valves, piped as in Figure 3 of this Guide, for the IPP. See Figure 31b for a
Figure 31a Typical radiant circuit piping - single supply temperature

Room temperature sensor or thermostat Primary loop (from boiler)
Return temperature sensor
P1
Purging valves
IPC Injection pump control
IPP-150 Injection pump panel
P2
Supply temperature sensor
Valve actuators optional
Manifold location A
Purge valves & air vents Valve actuators optional
Manifold location B
specific example of substituting dual mixing valves for the IPP of Figure 31a.
Prad.cdr
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Part Number 650-000-240/1098
Single supply temperature using dual mixing valves

Figure 31b Typical radiant circuit piping single supply temperature substituting dual mixing valves for the IPP Panel of Figure 31a
Thermostat
Figure 31b is an example of directly substituting a dual mixing valve configuration for the IPP panel. The piping schematics for Systems CP-2 through CP-12 in Radiant heating system examples all indicate how to substitute the mixing valve arrangement. Note the special case of System CP-4, in which two radiant circuits are supplied off of the primary circuit. When substituting mixing valves for the IPP in this case, note that only one boiler protection mixing valve is needed not two. Other piping methods are possible if designed and installed to meet the requirements of the system and the boiler used. Whatever piping method you use, it must provide control of the return water temperature to the boiler if the boiler manufacturer specifies a minimum return water temperature. The mixing valves may be either self-contained, remote bulb or motorized. If motorized, they may be operated by an electronic control, allowing outdoor reset if desired. AlumiPex manifolds are shown in the example diagrams in this Guide with and without manifold valve actuators. Use actuators when you wish to provide zone control. When using actuators and continuous operation of the pump, install a by-pass pressure regulator across the supply and return connections of the circuit. This will protect the pump from cavitation when the zone valves close off. (See Figures 65 and 67 for examples.)
Primary loop (from boiler)

Mixed Cold Hot
Purging valves
Cold Mixed Hot
Heating system pump
Mixing valve arrangement substituted for IPP panel

Manifold location A
Purge valves & air vents Valve actuators optional
When all manifolds in a circuit must receive the same temperature water, use the basic piping shown in Figure 31a or Figure 31b. For applications involving multiple manifolds that require different supply temperatures, use the piping shown in Figure 32 or Figure 33, on the following pages.
Manifold location B
Pradmv.cdr
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Piping radiant circuits - continued

Multiple supply temperatures
Use piping as shown in Figure 32 when multiple supply temperatures are needed. In this example, the loops connected to Manifold location B require hotter water than those connected to Manifold location A. The mixing valve reduces the IPP output temperature to give two temperature control. The injection pump panel provides water to the heating circuit at the temperature needed for the radiant loops connected to Manifold location B, the higher temperature circuit.
Manifold location A, the lower temperature circuit,
Figure 32 Typical radiant circuit piping - multiple supply temperatures from single injection pump panel
is connected to a crossover bridge containing a balancing valve, item 1. This valve provides a pressure drop in the bridge to match the pressure drop through the loops connected at Manifold location B. Partially close the valve until the required flow is achieved through the Manifold location B loops. Lower temperature water is supplied to the Manifold location A loops by the mixing valve, item 2. This valve mixes cooler return water with the supply water from the crossover bridge to provide the desired temperature. (You can substitute a two-way valve combined with a manual balancing valve for the 3-way mixing valve.) Outdoor reset response If the IPC is operated in reset mode, it will reset the supply temperature at the location of the IPC supply sensor. So, the reset will be based on the supply temperature and reset curve needed for the higher temperature radiant circuit. The low temperature circuit will not be reset until the heating curve drops below the setpoint of the low temperature circuit mixing valve. Example: The high temperature circuit is set for a reset ratio of 1 and a starting point temperature of 70 F. The low temperature circuit mixing valve is set for a temperature of 100 F. The IPC supply temperature to the radiant circuits will be above 100 F except when the outdoor temperature is 40 F or higher. (Since the supply temperature is
Tsupply = Tstarting + reset ratio x (Tstarting - Toutside) = 70 F + 1 x (70 F - 40 F) = 100 F
P1
Purging valves
IPP-150 Injection pump panel

1
Balancing valve
P2
Max 4 pipe diameters
2
Mixing valve
H M C
Circulator
Manifold location A (low temp)

Purge valves & air vents
Valve actuators required
At lower outside temperatures, the supply temperature will always be above 100 F, so no reset will be seen in the low temperature circuit.
NOTE: You can substitute dual mixing valves, piped as in Figure 3 of this Guide, for the IPP Injection Pump Panel.
Manifold location B (high temp)

Prad2.cdr
50
Part Number 650-000-240/1098
Multiple supply temperatures

Figure 33 is a system similar to that shown in Figure 32. In this case, however, each of the radiant circuits is connected to a crossover bridge off a primary supply from the injection pump panel. With this arrangement, all of the radiant circuits have access to the hottest supply water from the pump panel. This maximizes the output from the IPP and reduces the flow required in the radiant primary loop. Each of the radiant circuits requires its own circulator for this system to work. Manifold valve actuators are optional. Adjust the balancing valves (item 1) to regulate the amount of supply wter flowing through each of the crossover bridges. Use this piping design for larger buildings with widely spaced manifolds. Outdoor reset response Response will be similar to the discussion regarding Figure 32. The IPC will control the supply temperature and reset based on the needs of the highest temperature circuit. The low temperature circuit (with mixing valve) will only reset for those times when the IPC supply temperature is regulated below the setting of the mixing valve. All other circuits will experience some effects of reset because the flow rate is fixed by the balancing valve and the circuit pump. As the water supply temperature drops, the temperature to each circuit will drop as well, resulting in a reset effect even for lower temperature circuits.
NOTE: You can substitute dual mixReturn temperature sensor
Figure 33 Typical radiant circuit piping - multiple supply temperatures from single injection pump panel, using primary/secondary piping in radiant circuits
IPC
Injection pump control
Manifold location A
P1
Purging valves
IPP-150
Injection pump panel
P2
1
Balancing valve Max 4 pipe diameters Max 4 pipe diameters
2
Mixing valve
H M C
Circulator
1
Balancing valve
1
Balancing valve
Manifold location B (low temp)

ing valves, piped as in Figure 3 of this Guide, for the IPP Injection Pump Panel.
Part Number 650-000-240/1098
This diagram is schematic only. It does not indicate vertical placement of components. Flow/check valves are omitted because vertical placement is unspecified. Locate flow/check valves as needed when applying.
Manifold location C
Prad3.cdr
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XI
Domestic water heating

Many of the example systems in this Guide include piping for indirect water heaters. The Weil-McLain PLUS and GOLD Plus indirect water heaters provide high recovery rates and efficient supply of domestic water. They can be installed effectively in radiant heating systems as shown by the examples. water storage tank calls for heat. Using domestic priority generally allows a smaller boiler, since there is no overlap in heating and domestic water heating. Most residential installations work well with domestic priority because the domestic water and space heating peaks occur at different times. Several methods are shown in the example systems, including
Diverter valve method (suggested for use with GV
Domestic priority
Domestic priority means the indirect water heater receives priority over all other heating functions when the domestic
Override priority relay by connecting the TDR relay contacts across the DHW Priority relay contacts as shown below . . .
Figure 34 Priority override relay
boilers only), as shown in Figure 37 and in system CP-8. The diverter valve diverts all heating water flow to the water heater when it calls for heat. The diverter valve method has a slight disadvantage over other methods shown because the pressure drop through the diverter valve reduces flow available to the system.
First-in-line priority (can be used with all boilers),
TDR2 (pump-disable override)

Primary pump and/or baseboard pump or pump relay
DHW2
as shown in system CP-6 through CP-7. The piping strategy of Figure 36 always provides this priority option because the supply water is taken directly from the boiler supply piping. For first-in-line priority, the heating water supply to the indirect water heater is taken before it reaches other heating sources. This isn't true priority unless the flow to the other heating applications is temporarily interrupted on a call for heat from the indirect water heater. This can be done using the IPC control and relays as shown in the corresponding wiring diagrams for systems CP-6, CP-7, and CP-9 through CP-11.
Flow interruption priority - can be applied in any of the systems CP-6 through CP-11 by using relays as shown in the wiring diagrams. When the indirect water heater calls for heat, the relay(s) stops the pumps feeding other heating applications.
heating pump disable
120 VAC
24 VAC DHW tank aquastat DHW
TDR
Priority override option If the building is frequently unoccupied (weekend house, f or example), consider installing a time delay relay to prevent the possibility of extended no-heat periods should the domestic priority system fail for any reason. This relay, usually selected as a one-hour delay, can be introduced to the DHW relay circuit to allow system heating should the DHW relay remain activated longer than the time period of the relay. See Figure 34.
Part Number 650-000-240/1098
TDR1 (call-for-heat-disable override)

24 vac to IPC through valve actuator end switches - or 24 vac to baseboard pump relay through zone valve end switches
DHW1
call-for-heat disable
52
The following domestic water heating piping alternatives can be applied in most radiant heating applications. They are shown here separated from the remainder of the piping for ease of discussion.
means hot water must flow throughout the primary piping even during the summer.
Figure 36 provides a means of circulating water only
Piping strategies
The indirect water heater can be connected to the primary/secondary piping in several ways, depending on the desired operating characteristics. For conventional boilers we recommend only the methods of Figure 35 and 36. For GV boilers use only the methods of Figures 35 or 37.
Figure 35 shows the water heater connected as a secondary circuit off of the primary. You will find this
through the indirect water heater circuit during the nonheating months. Water is taken from the boiler supply and returned directly to the boiler return. The primary pump does not have to operate during domestic water heating cycles. This eliminates heat loss from the primary piping during non-heating periods. For installations in which the primary piping runs throughout the building, this method can save considerable energy. You will find this method used in systems CP-8 and CP-10.
Note re Figure 36 For systems piped with zone valve
zoning rather than circulator zoning, substitute a zone valve for the pump.
Figure 37 uses a diverting valve to switch water flow
method used in systems CP-6 and CP-7. System CP-12 uses a similar approach, but takes the secondary circuit tees from the boiler supply water before it reaches the primary loop. These systems require water to be flowing in the primary loop (or boiler supply piping for system CP-12) in order to heat the indirect water heater. This Figure 35 Water heater piped as secondary circuit
DHW outlet
flow/check valve
from the heating circuit to the domestic water heater during a DHW heating cycle. It provides domestic priority and prevents flow of hot water through the heating circuits during non-heating periods. This method is used in system CP-9. Figure 37 Diverter valve domestic water heater piping
to system return
Figure 36 Water heater piped directly across suppy and return

cold water inlet
flow/check valve
DHW outlet
cold water inlet
DHW outlet
cold water inlet
GOLD Plus water heater

DHW diverter valve
normally closed normally open common from boiler
Circulator
Circulator
Part Number 650-000-240/1098
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Radiant heating system examples

System System description Boiler Applications
Finned tube baseboard Small radiant circuit Radiant heating only Pages
CP-1 CP-2
Adding a small zone of radiant heating Conventional to an existing baseboard heating system. GV boiler supplying an injection pumping panel Conventional boiler supplying an injection pumping panel Two-temperature radiant heating system using two injection pumping panels Two-temperature radiant heating system using one injection pumping panel and a mixing valve GV boiler
56 - 59
60 - 63
CP-3
Conventional
Radiant heating only
64 - 67
CP-4
Conventional
68 - 71
CP-5
Conventional
72 - 75
CP-6
Radiant heating and domestic water heating with conventional boiler - DHW Conventional as a secondary circuit Radiant heating and domestic water heating with GV boiler - DHW as a secondary circuit Radiant heating and domestic water heating with conventional boiler independent DHW operation Radiant heating and domestic water heating with GV boiler - DHW through diverting valve Radiant heating, domestic water conventional boiler GV boiler
Radiant heating Domestic hot water heating Radiant heating Domestic hot water heating Radiant heating Domestic hot water heating Radiant heating Domestic hot water heating Radiant heating Domestic hot water heating Baseboard heating Radiant heating Domestic hot water heating Baseboard heating Radiant heating Domestic hot water heating Baseboard heating
76 - 78
CP-7
80 - 83
CP-8
Conventional
84 - 87
CP-9
Conventional
88 - 91
CP-10 heating and baseboard heating with

Radiant heating, domestic water boiler
Conventional
92 - 97
CP-11 heating and baseboard heating with GV GV boiler

Radiant heating, domestic water multiple boilers
98 - 103
CP-12 heating and baseboard heating with
Conventional
104 - 109
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Part Number 650-000-240/1098
Figure 38 Symbol legend for system piping drawings
Automatic air vent
Gate valve
Air separator
Mixing valve
Flow/check valve
Diaphragm expansion tank
Circulator or pump
Pressure gauge
Ball valve
Pressure reducing valve
Drain cock
Backflow preventer
Globe valve
Balancing valve
Swing check valve
Cold water fill line detail
To expansion tank
Part Number 650-000-240/1098
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System CP-1 Adding a small zone of radiant heating to an (pages 58 59) existing baseboard heating system
Purpose This system shows two methods of adding a small radiant heating zone to an existing
baseboard heating system. The radiant heating zone must be small and low mass - it cannot be a slab on grade installation. Use only for small zone thin slab or suspended floor radiant plate systems.
This example is the only exception to the requirement for control of the boiler return temperature
(other than high temperature radiant applications for suspended floor heating as discussed on page 46.) Return water temperature regulation is not needed in this example because the radiant load is small and low mass, so the radiant load won't greatly reduce the return temperature.
Two alternatives to piping the radiant zone are illustrated Alternate 1a - "slave" operation The radiant branch must be connected as close to the end of the baseboard loop as possible,
to avoid reducing the water temperature (and output) to baseboards downstream.
Install the radiant branch as a secondary circuit off of the baseboard loop. This piping
method will make no change in the flow of the primary (baseboard) loop.
This piping option is called a "slave" zone because heat can be supplied to the radiant heating
circuit only when the baseboard loop pump operates. Since the baseboard zone thermostat controls the boiler and the baseboard loop pump, the radiant zone can only operate when the baseboard thermostat is calling for heat. Use this piping option when you are sure the baseboard zones will always need heat at the same times as the radiant zone.
Flow of hot water from the baseboard loop into the radiant circuit is controlled by the nonelectric thermostatic valve (mixing valve). This valve may be remote bulb, as shown, or selfcontained.
Operation - Alternate 1a On call for heat from the radiant zone thermostat, a pump relay is activated, powering the
radiant circuit pump, P2.
The boiler and baseboard loop pump will operate only when there is a call for heat from the
baseboard thermostat.
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Part Number 650-000-240/1098
System CP-1
Alternate 1b - "independent" operation This option takes the radiant heating water directly across the boiler supply and return,
allowing it to operate independently of the baseboard circuit pump. You must install a flow/ check valve in the baseboard circuit if not already installed when using this option, to prevent short circuiting the flow of the radiant pump.
Use this alternative when you want the radiant zone to be capable of operation even when
there is no demand from the baseboard zones. Do not use alternate 1b with a GV boiler - flow through the boiler can only be controlled by the integral pump.
The non-electric thermostatic valve (mixing valve) regulates flow of hot water from the
baseboard circuit into the radiant circuit. This valve may be remote bulb, as shown, or selfcontained.
Operation - Alternate 1b The baseboard pump operates on call for heat from the baseboard thermostat, powered
through the pump relay. This relay also provides the call for heat signal to the boiler.
A second relay is operated by the radiant zone thermostat. On call for heat from this thermostat,
the radiant circuit pumps are activated pump P2 (boiler pump that circulates water through the crossover bridge from boiler supply to return) and pump P3 (pump that circulates water through the radiant tubing).
Part Number 650-000-240/1098
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Figure 39 - System CP-1 Adding a small zone of radiant heating to an existing baseboard heating system
Radiant heating system examples CP1

Primary pump
To fill line
P1
Flow/check valve (add if using alternate 1b)
Existing baseboard circuit

Note 2
Non-electric thermostat valve (set for design water temp.)

Note 2 Purging valves
P2
Non-electric thermostat valve (set for design water temp.)
Purging valves
Capillary
Sensor bulb
Safety controls (as required by local codes)
P2
Sensor bulb
P3
Valve actuators optional Purge valves & air vents
Boiler
"Slave" floor heating zone (alternate 1a)

"Independent" floor heating zone (alternate 1b)
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel.
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Part Number 650-000-240/1098
Figure 40a - System CP-1a Slave floor heating zone schematic wiring - 24 VAC zone valve When using the optional radiant circuit pump relay, inform the owner that the thermostat only controls the pump. It cannot operate the boiler. Heat will be available to the radiant circuit only when the baseboard thermostat(s) is calling for heat. The radiant thermostat only serves the purpose of limiting the heat input to the radiant zone.
Service 120 VAC switch
L1
Safety controls, if reqd by local codes
H N G
B1 B2
Burner
120 VAC
Transformer 120vac/24vac
24 VAC
Radiant pump relay
Floor heating pump P2

T T
Boiler
C1 C2
Radiant zone thermostat
Baseboard pump
P1
Baseboard zone thermostat
NOTE Floor heating pump, P2, can be operated by wiring in parallel with pump P1. This would eliminate the transformer, pump relay and radiant zone thermostat.
Figure 40b - System CP-1b Independent floor heating zone schematic wiring diagram
Service switch
120 VAC
L1
Floor heating pump
P3
120 VAC
Boiler pump Transformer 120vac/24vac
24 VAC
relay
P2
floor heating zone thermostat
Baseboard pump
P1
baseboard zone thermostat
relay
Boiler
T T H N G B1 B2
Safety controls, if required by local codes
Burner
C1 C2
Notes
1. This drawing is conceptual only. It shows representative system wiring. Weil-McLain does not represent that this drawing meets any particular mechanical, electrical, or building codes. All wiring must be installed in accordance with: In the USA - the latest version of the National Electrical Code (N.E.C.), as well as any other National, State or Local code requirements having jurisdiction. In Canada - CSA C22.1 (C.E.C.) Part 1, as well as any other National, Provincial or Local code requirements having jurisdiction. The installer is responsible for inclusion of all required safety devices, or other miscellaneous hardware not shown on drawing. 2. The minimum wire gauge used for all low voltage circuits shall be 18 AWG unless otherwise required by code(s) having jurisdiction. Part Number 650-000-240/1098
59
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(pages 62 63)
System CP-2 GV boiler supplying an injection pump panel

Purpose Provide heating water to radiant circuits, using a control and injection pump that regulate
radiant circuit supply temperature and maintain minimum boiler return temperature.
Pumps and piping

Primary circuit
The GV integral pump provides primary circuit flow.

Radiant circuits
The Injection Pump Panel (IPP) includes the injection pump and radiant circuit pump. (For
applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.)
Radiant heating circuits System CP-1 shows two manifold locations. The same piping design can be used for multiple
manifolds.
Manifold valve actuators are optional, but recommended as discussed in Zoning radiant
heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone
thermostat or a dry contact that closes on a call for heat. Alternatively, use an indoor sensor or zone control.
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Part Number 650-000-240/1098
System CP-2
Controls and wiring

Injection pump control (IPC IPC) IPC
The IPC is included with the IPP panel (or purchased separately when using field-constructed
injection mixing systems).
The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor).
You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback, allowing heating circuit regulation based on space temperature response.
The IPC controls the injection pump (P2) and radiant circuit pump (P3). The GV boiler
integral pump (P1) operates with the boiler (activated by the GV controls).
Use IPC dip switch 2 to set radiant circuit pump (P3) operation - DOWN for intermittent
operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close.
Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an
indoor sensor is connected to the IPC.
Operation On call for heat from a radiant zone thermostat or actuator, the IPC activates the injection
pump (P2), the radiant circuit pump (P3), and the boiler. The boiler activates the integral pump (P1), initiating flow in the primary circuit.
The IPC regulates the flow rate of the injection pump (P2), increasing flow to raise the supply
temperature, or lowering flow to reduce it.
If boiler return temperature drops below the preset limit (130 F), the IPC reduces injection
flow (reducing the temperature drop in the primary circuit).
Part Number 650-000-240/1098
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Figure 41 - System CP2 GV boiler supplying an injection pump panel
Air separator
Primary circuit
IPC
P2
Purging valves
IPP
P3
Alternate piping
(using mixing valves)
Substitute for IPP panel

Primary circuit return Cold
Mixed Hot Primary circuit supply
Manifold location A GV Boiler P1

Cold Mixed Hot Fill Heating system pump Supply to heating system
Manifold location B
Return from heating system
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel. 3. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring for this piping alternative.
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Part Number 650-000-240/1098
Figure 42 - System CP2

Power
Schematic wiring diagram

Call For Heat Min Boiler Return Temp Outdoor Temp Shutoff
Reset On
123
Continuous System Pump Zone Control Input
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2
These pumps are mounted and pre-wired on the IPP panel.
Indoor sensor (if used in lieu of zone t-stats)
Supply & return sensors
P3
120 VAC Transformer 120vac/24vac

Minimum rating 10 va plus 6 va per AlumiPex valve actuator connected
Outdoor sensor, required only if using outdoor reset.
24 VAC
Room thermostat
Room thermostat
4-wire actuator See note 3
2-wire actuator
T L
See note 3 Valve actuator
Valve actuator Valve actuator To additional actuators
N G
P1
GV Boiler
Notes
1. This drawing is conceptual only. It shows representative system wiring. Weil-McLain does not represent that this drawing meets any particular mechanical, electrical, or building codes. All wiring must be installed in accordance with: In the USA - the latest version of the National Electrical Code (N.E.C.), as well as any other National, State or Local code requirements having jurisdiction. In Canada - CSA C22.1 (C.E.C.) Part 1, as well as any other National, Provincial or Local code requirements having jurisdiction. The installer is responsible for inclusion of all required safety devices, or other miscellaneous hardware not shown on drawing. 2. The minimum wire gauge used for all low voltage circuits shall be 18 AWG unless otherwise required by code(s) having jurisdiction. 3. Multiple valve actuators may be powered through a common thermostat for rooms/zones having multiple radiant circuits. End switches are optional on all but one valve actuator wired in this manner. 4. See Weil-McLain installation instructions for specific details on installing the boiler, and injection pump panel. Part Number 650-000-240/1098
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System CP-3 Conventional boiler supplying an injection pump (pages 66 67) panel
Purpose
Provide heating water to radiant circuits, using a control and injection pump that regulate radiant circuit supply temperature and maintain minimum boiler return temperature.
Pumps and piping

Primary circuit
The primary pump can be as supplied with the boiler or purchased separately. Residential packaged boilers may have the pump mounted on the return piping at the boiler. The pump can be used in this location provided the expansion tank or compression tank and fill line are correctly located.
Radiant circuits
The Injection Pump Panel (IPP) includes the injection pump and the radiant circuit pump. (For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.)
Radiant heating circuits

System CP-2 shows two manifold locations. The same piping design can be used for multiple manifolds. Manifold valve actuators are optional, but recommended as discussed in Zoning radiant heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone thermostat or a dry contact that closes on a call for heat. Alternatively, use an indoor sensor or zone control.
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Part Number 650-000-240/1098
System CP-3
Controls and wiring

The IPC (Injection Pump Control) is included with the IPP panel (or purchased separately when using field-constructed injection mixing systems). The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor). You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response. The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump (P1) operates with the boiler (activated by the boiler controls). Use IPC dip switch 2 to set radiant circuit pump (P3) operation - DOWN for intermittent operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close. indoor sensor is connected to the IPC.
Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an Operation
On call for heat from a radiant zone thermostat or actuator, the IPC activates the injection pump (P2), the radiant circuit pump (P3), and the boiler. The boiler activates the primary pump (P1), initiating primary circuit flow. The IPC regulates the flow rate of the injection pump (P2), increasing flow to raise the supply temperature, or lowering flow to reduce it. If boiler return temperature drops below the preset limit (130 F), the IPC reduces injection flow (reducing the temperature drop in the primary circuit).
Part Number 650-000-240/1098
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Figure 43 - System CP3 Conventional boiler supplying an injection pump panel

Primary pump
Fill
P1
Primary circuit
IPC
P2
Purging valves
IPP
P3
Alternate piping

Manifold location A Boiler

Cold Mixed Hot
Heating system pump Supply to heating system
Manifold location B
Notes
66
Part Number 650-000-240/1098

Power

Reset On
123
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2
P3
Indoor sensor (if used in lieu of zone t-stats)

Oil-fired Boiler
T L N G
24 VAC
Room thermostat
Room thermostat
2-wire actuator
B1 B2
Burner
C1 C2
See note 3 Valve actuator Valve actuator Valve actuator To additional actuators Primary Pump
P1
Notes
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System CP-4 Two-temperature radiant heating system using (pages 70 71) two injection pump panels
Purpose Provide heating water to two radiant circuits - each requiring a different temperature. The
controls and injection pumps regulate radiant circuit supply temperature and maintain minimum boiler return temperature.
Pumps and piping

Primary circuit
The primary pump can be as supplied with the boiler or purchased separately. Residential packaged boilers may have the pump mounted on the return piping at the boiler.
The pump can be used in this location provided the expansion tank or compression tank and fill line are correctly located.
Radiant circuits
The Injection Pump Panel (IPP) includes the injection pump and the radiant circuit pump.
(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.)
Radiant heating circuits Install the injection pump panel for the higher temperature subsystem upstream of the lower
temperature circuit injection pump panel to assure hotter supply water. This is illustrated in system CP-4, where Circuit #1 is the higher temperature circuit.
System CP-4 shows two manifold locations for Circuit #2 and one for Circuit #1. The same
piping design can be used for multiple manifolds.
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Part Number 650-000-240/1098
System CP-4
Controls and wiring

An IPC is included with each IPP panel (or purchased separately when using field-constructed
injection mixing systems).
You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response.
The IPC's control the injection pumps (P2 and P4) and radiant circuit pumps (P3 and P5).
The primary pump (P1) operates with the boiler (activated by the boiler controls).
On each IPC, use dip switch 2 to set radiant pump operation - DOWN for intermittent
operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close.
Operation
On call for heat from a radiant zone thermostat or actuator, the corresponding IPC activates
its injection pump, radiant circuit pump and the boiler. The boiler activates the primary pump (P1), initiating primary circuit flow.
The IPC's regulate the injection pump flow rates, increasing flow to raise the supply temperature,
or lowering flow to reduce it.
Part Number 650-000-240/1098
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Fill

Primary pump
P1
Primary circuit
H C M Primary circuit return Note 2 Note 2 Primary circuit supply
#2
C M H Heating system pump
#1
C M H Heating system pump Return from heating system Supply to heating system
Alternate piping (using mixing valves) Substitute for IPP panels
Supply to heating system
IPC
IPC
P2
Safety controls (as required by local codes) Purging valves Outdoor sensor
P4
Purging valves
IPP
Injection pump panel #2
#2
P3
IPP
Injection pump panel #1
#1
P5
No valve actuators are shown here in order to provide for continuous circulation.
Manifold location A
Manifold location A
Boiler
No valve actuators are shown here in order to provide for continuous circulation.
Manifold location B
NOTICE IPP #1, with HIGHER supply temperature requirement, is installed upstream on the primary circuit (in order to receive the highest water temperature).
Figure 45 - System CP4 Two-temperature radiant heating system using two injection pump panels
Notes
70
Part Number 650-000-240/1098
Figure 46 System CP4 Schematic wiring diagram

IPC #1
Reset On
Continuous Pump Zone Control Indoor Sensor On/Off System Pump
Reset On
Reset Off
Reset Off
Supply Temp.
Injection Pump Speed
Max. Supply Temp.
Supply Temp.
Max. Supply Temp.
L1
120 VAC
N
120 V (ac)
Supply Temp Ratio
IPC #2
Supply Temp Ratio
Power
Inj Sys Pump Pump
Reset inputs Zone or Outdoor Indoor Sensor
Required sensors Boiler Radiant Return Supply
Outdoor Temp System Shutoff From To Radiant Boiler T-stat T-T
120 V (ac)
Power
Inj Sys Pump Pump
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2
P3
P3 and P4 are mounted and pre-wired on the IPP panel.
Indoor sensor, used in lieu of zone t'stats
Outdoor sensor, used only for reset operation
P4
P5
Indoor sensor, if used in lieu of zone t'stats
Outdoor sensor, used for reset if desired
NOTE that IPC #1 is set up for thermostat operation. IPC #2 is set up for use with indoor sensor and continuous operation circulator. This configuration does not require a voltage applied to terminals 15 and 16.

Oil-fired Boiler
T L N G
24 VAC
Room thermostat
Room thermostat
2-wire actuator
B1 B2
Burner
C1 C2
See note 3 Valve actuator Valve actuator Valve actuator To additional actuators
P1
Primary pump
Notes
71
XII
System CP-5 Two-temperature radiant heating system using (pages 74 75) one injection pump panel and a mixing valve
Purpose Provide heating water to two radiant circuits - each requiring a different water supply
temperature. The control and injection pump provide water hot enough for the higher temperature radiant circuit, and maintain a minimum boiler return temperature. A mixing valve regulates the supply water to the lower temperature circuit.
Pumps and piping

Primary circuit
Radiant circuits
Pipe the radiant circuit requiring the higher water temperature (Circuit #2 in system CP-5)
directly off of the radiant supply line as shown.
Install a bridge for connection of the lower temperature radiant circuit (Circuit #1 in system
CP-5). Install a balancing valve in the bridge as shown. Throttle the valve enough to push the required water through radiant Circuit #2.
Provide a pump and a three-way mixing valve for the lower temperature circuit (Circuit #1 in
CP-5). Assure that the pump is sized to handle the mixing valve pressure drop.
System CP-5 shows one manifold location for each of the radiant circuits. The same piping
design can be used for multiple manifolds.
72
Part Number 650-000-240/1098
System CP-5
Controls and wiring

An IPC (Injection Pump Control) is included with the IPP panel (or purchased separately
when using field-constructed injection mixing systems).
You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response.
The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump
(P1) operates with the boiler (activated by the boiler controls).
The low temperature radiant circuit pump (P4) operates when the low temperature circuit
relay is activated through the actuator end switches.
On each IPC, use dip switch 2 to set radiant pump operation - DOWN for intermittent
operation, UP for continuous pump operation. Because of the bridge in the radiant circuit piping, the radiant circuit pump always has a flow path, even if manifold valve actuators are used. This eliminates the need for a differential pressure by-pass valve when using manifold valve actuators with continuous pump operation.
Operation On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection
pump, radiant circuit pump and the boiler. The boiler activates the primary pump (P1), initiating primary circuit flow.
On call for heat from one of the low temperature circuit actuator end switches, the low
temperature circuit relay is activated. This activates pump P4 and signals the IPC for heat.
The IPC regulates injection pump flow rate, increasing flow to raise supply temperature - or
lowering flow to reduce it. Set the IPC supply temperature as needed for the higher temperature circuit (Circuit #2 in CP-5). The mixing valve will automatically regulate the supply temperature to the lower temperature circuit (Circuit #1 in CP-5).
Part Number 650-000-240/1098
73
XII
Figure 47 - System CP5 Two-temperature radiant heating system using one injection pump panel and a mixing valve

Primary pump
Fill
P1
Primary circuit
IPC
P2
Purging valves
IPP
Note 2
P3
Balancing valve
Alternate piping
2
Mixing valve
H M C
P4
Pump

Valve actuators optional Mixed Hot Primary circuit supply
Circuit #1 (lower temp)
Boiler
Valve actuators required Cold Mixed Hot
Circuit #2 (higher temp)
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel. 4. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring for this piping alternative.
74
Part Number 650-000-240/1098
Figure 48 - System CP5 Schematic wiring diagram

Reset On
Reset Off
Supply Temp.
Max. Supply Temp.
IPC #2
L1
120 VAC
N
120 V (ac)
Supply Temp Ratio
Power
Inj Sys Pump Pump
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2

Minimum rating 10 va plus 6 va per AlumiPex valve actuator connected Low temp circuit relay
P3
Indoor sensor, if used in lieu of zone t'stats
Outdoor sensor, used for reset if desired
P4
Low temp circuit pump
24 VAC
Low temperature zones . . . .
Room thermostat
Room thermostat
2-wire actuator
See note 3 Valve actuator Valve actuator Valve actuator
Oil-fired Boiler
T L N
High temperature zones . . . .
To additional actuators (low temp circuit)

Safety controls, if required by local codes 4-wire actuator See note 3 Burner 2-wire actuator
Room thermostat
Room thermostat
B1 B2 C1 C2
See note 3 Valve actuator Valve actuator Valve actuator
To additional actuators (high temp circuit)
P1
Primary pump
Notes
75
XII
System CP-6 Radiant heating and domestic water heating with (pages 78 79) conventional boiler - DHW as a secondary circuit
Purpose Provide radiant heating and domestic water heating (with optional domestic priority). The
control and injection pump regulate radiant circuit supply temperature and maintain minimum boiler return temperature.
Pumps and piping

Primary circuit
Radiant circuits
(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.)
System CP-6 shows two manifolds location for the radiant circuits. The same piping design
can be used for multiple manifolds.
Water heater circuit
Provide a pump with the domestic water heater, sized to give the required flow through the
heater for the supply water temperature available.
Pipe the domestic water circuit as the first branch off the primary circuit. This assures the
hottest possible supply water temperature.
76
Part Number 650-000-240/1098
System CP-6
Controls and wiring

Radiant heating controls
An IPC (Injection Pump Control) is included with the IPP panel (or purchased separately when using fieldconstructed injection mixing systems).
The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor). You can connect an
indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response.
The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump (P1) operates with
the boiler (activated by the boiler controls).
Use IPC dip switch 2 to set radiant circuit pump operation - DOWN for intermittent operation, UP for continuous
pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close.
Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an indoor sensor is
connected to the IPC.
DHW controls
Provide a DHW relay as shown in the wiring diagram. Operation

The primary pump must operate to provide heating water to the domestic water heater. Heating water must flow
through the primary piping during any domestic water heating cycle, including non-heating season periods. This approach is best used on systems with short primary circuit piping, to minimize non-heating season piping losses. See systems CP-7 and CP-8 for alternate designs that do not require primary circuit operation during domestic water heating cycles.
On call for heat from the water heater tank aquastat, the DHW relay is activated. This relay activates the boiler and
the DHW pump (P2). The boiler, in turn, activates the primary pump, P1. If wired for domestic priority, the DHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P3). The radiant circuit pump (P4) will turn off as well unless IPC dip switch #2 is set for continuous pump operation.
Radiant heating
On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump, radiant circuit
pump and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary circuit. If the DHW relay is wired for domestic priority, the IPC will not sense the call for heat until the domestic water heating cycle is completed.
The IPC regulates injection pump flow rate, increasing flow to raise the supply temperature, or lowering flow to
reduce it.
If boiler return temperature drops below the preset limit (130 F), the IPC reduces injection flow (reducing the
temperature drop in the primary circuit).
Part Number 650-000-240/1098
77
XII
Figure 49 - System CP6 Radiant heating and domestic water heating with conventional boiler - DHW as a secondary circuit
Fill
Primary pump
P1
Primary circuit
DHW outlet
flow/check valve
cold water inlet
IPC P3
Return temperature sensor Purging valves
note 2
IPP P2 GOLD Plus water heater

Alternate piping
P4

Manifold location A
Boiler
Cold Mixed Hot
Manifold location B
Notes
78
Part Number 650-000-240/1098

Power

Reset On
123
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
Indoor sensor, if used in lieu of zone t-stats
P3
P4

T T
L N
Oil-fired Boiler
DHW relay Safety controls, if required by local codes
24 VAC
G B1
Room thermostat
To additional actuators
Room thermostat
4-wire actuator See note 3 Valve actuator
DHW tank aquastat 2-wire actuator
B2
Burner
C1 C2
Valve actuator
Relay shown wired for domestic priority. Add jumper, shown in red above, to remove priority.
P2
DHW pump
P1
Primary pump
Notes
79
XII
System CP-7 Radiant heating and domestic water heating with (pages 82 83) GV boiler - DHW as a secondary circuit
Pumps and piping

Primary circuit
System CP-7 uses the integral pump in the GV boiler for primary loop circulation. If a higher
flow rate is required, pipe the GV boiler and water heater on a secondary circuit and provide a separate pump for the primary circuit.
System CP-7 shows two manifold locations for the radiant circuits. The same piping design
heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone thermostat or a dry contact that closes on a call for heat. Alternatively, use an indoor sensor or zone control. Water heater circuit
Pipe the domestic water circuit as the first branch off of the primary. This assures the hottest
possible supply water temperature.
80
Part Number 650-000-240/1098
System CP-7
Controls and wiring

The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump (P1) is integral to the
GV boiler, and is activated by the boiler controls.
DHW controls
Provide a DHW relay, as shown in the wiring diagram. Operation

The primary pump (P1, integral to the GV boiler) must operate to provide heating water to the domestic water
heater. Heating water must flow through the primary piping during any domestic water heating cycle, including non-heating season periods. This approach is best used on systems with short primary circuit piping, to minimize non-heating season piping losses. See systems CP-7 and CP-8 for alternate designs that do not require primary circuit operation during domestic water heating cycles.
the DHW pump (P2). The boiler, in turn, activates the primary pump (P1). If wired for domestic priority, the DHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P3). The radiant circuit pump (P4) will turn off as well unless IPC dip switch #2 is set for continuous pump operation.
Radiant heating
On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P3), radiant
circuit pump (P4) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. If the DHW relay is wired for domestic priority, the IPC will not sense the call for heat until the domestic water heating cycle is completed.
reduce it.
Part Number 650-000-240/1098
81
XII
Figure 51 - System CP7 Radiant heating and domestic water heating with GV boiler DHW as a secondary circuit
Primary circuit
DHW outlet
flow/check valve
cold water inlet
IPC
P3
note 2
Purging valves
IPP P2
Alternate piping
P4



Manifold location B
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel. 4. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring for this piping alternative.
82
Part Number 650-000-240/1098

Power

Reset On
123
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
Primary circulator relay (24 VAC coil)
P3 P4 120 VAC Transformer 120vac/24vac

24 VAC
DHW relay
Room thermostat
Room thermostat
T
Relay shown wired for DHW priority. To remove priority, add red jumper where shown above.
T L N
Valve actuator Valve actuator
P2
DHW pump
G GV Boiler
P1
Notes
83
XII
System CP-8 Radiant heating and domestic water heating with (pages 86 87) conventional boiler - independent DHW operation
This system allows domestic water heating without flow in the primary circuit, reducing
piping losses during non-heating season periods.
Pumps and piping

Primary circuit
Radiant circuits
System CP-8 shows two manifold locations for the radiant circuits. The same piping design
Include a flow/check valve in the primary and water heater circuits, as illustrated, to prevent
flow short circuiting.
Connect the DHW supply directly off of the boiler supply piping. This assures the hottest
possible supply water temperature. Connect the DHW return to the boiler return piping.
84
Part Number 650-000-240/1098
System CP-8
Controls and wiring

DHW controls

the DHW pump (P2). The boiler, in turn, activates the primary pump, P1. If wired for domestic priority, the DHW relay turns off the primary pump (P1) and interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P3).
The radiant circuit pump (P4) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.
Radiant heating
circuit pump (P4) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary circuit. If the DHW relay is wired for domestic priority, the primary pump will not be powered and the IPC will not sense the call for heat until the domestic water heating cycle is completed.
reduce it.
Part Number 650-000-240/1098
85
XII
Figure 53 - System CP8 Radiant heating and domestic water heating with conventional boiler independent DHW operation

Flow/check valve
Flow/check valve Fill
Primary pump
P1
DHW outlet
cold water inlet
Primary circuit
IPC P3
Return temperature sensor Purging valves
IPP
DHW pump
P4
Alternate piping
P2

Manifold location A
Boiler
Cold Mixed Hot
Manifold location B
Notes
86
Part Number 650-000-240/1098

Power

Reset On
123
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P3
P4

T T
L N
Oil-fired Boiler
DHW relay Safety controls, if required by local codes
24 VAC
G B1
Room thermostat
Room thermostat
B2
Burner
C1 C2
Valve actuator Valve actuator Relay shown wired for domestic priority. Add (2) jumpers, shown in red above, to remove priority.
P2
DHW pump
P1
Primary pump
Notes
87
XII
System CP-9 Radiant heating and priority domestic water heating (pages 90 91) with GV boiler DHW through diverting valve
Purpose Provide radiant heating and domestic water heating with domestic priority. The control and
injection pump regulate radiant circuit supply temperature and maintain minimum boiler return temperature.
This system provides domestic water heating without flow in the primary circuit, reducing
piping losses during non-heating season periods.
Pumps and piping

Primary circuit
The GV boiler integral pump must provide flow for the water heater and primary circuits.
Radiant circuits
System CP-9 shows two manifold location for the radiant circuits. The same piping design
thermostat or a dry contact that closes on a call for heat.

The 3-way diverting valve is normally open to the radiant heating circuit (primary). It directs
flow through either the primary or domestic water circuit.
88
Part Number 650-000-240/1098
System CP-9
Controls and wiring

DHW controls

On call for heat from the water heater tank aquastat, the diverting valve directs flow to the water heater and the
DHW relay is activated. This relay activates the boiler. The boiler, in turn, activates the primary pump, P1. The DHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P2). The radiant circuit pump (P3) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.
Radiant heating
circuit pump (P3) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary circuit. When the DHW relay is activated, the IPC will not sense the call for heat until the domestic water heating cycle is completed.
reduce it.
Part Number 650-000-240/1098
89
XII
Figure 55 - System CP9 Radiant heating and domestic water heating with GV boiler DHW through diverting valve
DHW outlet
cold water inlet
Primary circuit
IPC
P2
Purging valves
GOLD Plus water heater DHW diverter valve

normally closed normally open common
IPP
P3
Alternate piping



Manifold location B
Notes
90
Part Number 650-000-240/1098

Power

Reset On
123
140 F
Reset Off
140 F
L1
120 VAC
System Pump
Boiler

Service switch
NRTL/C LR 58223
Made in Canada
RESET INPUTS
REQUIRED SENSORS
at least 300V
From Radiant T-stat
To Boiler T-T
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
Indoor sensor, (if used in lieu of zone t-stats)
P2
P3

24 VAC
DHW relay
Room thermostat
Room thermostat
T H
N
24VAC DHW diverter valve (energized on call for DHW)
G
P1
GV Boiler
Notes
91
XII
System CP-10 Radiant heating, domestic water heating and (pages 94 97) baseboard heating with conventional boiler
Purpose Provide multiple heating functions - radiant heating and baseboard heating plus domestic
water heating (with optional domestic priority). The control and injection pump regulate radiant circuit supply temperature and help maintain minimum boiler return temperature. This system provides domestic water heating without flow in the primary circuit, reducing piping losses during non-heating season periods. Two versions are shown one for baseboard zoning with zone valves (CP-10a) and the other for baseboard zoning with pumps (CP-10b).
Pumps and piping

Primary circuit
Radiant circuits
(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.) System CP-10 shows two manifold locations for the radiant circuits. The same piping design can be used for multiple manifolds. Manifold valve actuators are optional, but recommended as discussed in Zoning radiant heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone thermostat or a dry contact that closes on a call for heat.
heater for the supply water temperature available. Connect the DHW supply directly off of the boiler supply piping. This assures the hottest possible supply water temperature. Connect the DHW return to the boiler return piping. Include a flow/check valve in the primary and water heater circuits, as illustrated, to prevent flow short circuiting.
Baseboard circuits
The system illustration shows several options for baseboard circuit piping. Provide the
pumps needed for the baseboards. Each baseboard branch circuit off of the primary will require at least one pump, even if zoning with zone valves. Use flow/check valves in the baseboard circuits as illustrated. A flow/check is required in every loop when zoning with pumps. A flow/check is required on the return piping when the piping is above the primary unless a thermal trap is provided as shown.
92
Part Number 650-000-240/1098
System CP-10
Controls and wiring

Baseboard and DHW controls
Baseboard heating and domestic water heating are operated through a Multi-zone relay center, illustrated based
on zoning the baseboard heating with pumps. If zoning with zone valves, replace the thermostats shown connected to the relay center with the zone valve end switches. If domestic water heating priority is desired, add the DHW relay.
indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response. The IPC controls the injection pump (P10) and radiant circuit pump (P11). The primary pump (P1) operates with the boiler (activated by the boiler controls). Use IPC dip switch 2 to set radiant circuit pump operation - DOWN for intermittent operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close. Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an indoor sensor is connected to the IPC.
Operation
On call for heat from the water heater tank aquastat, the DHW circulator is activated by the relay center and the
DHW relay (optional) is activated. If wired for domestic priority, the DHW relay turns off the primary pump (P1) and interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P10). The radiant circuit pump (P11) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.
Baseboard heating
On call for heat from a baseboard zone, the relay center activates the zone pump and turns on the boiler. The
boiler, in turn, activates the primary pump (P1). If domestic water priority is installed, the primary pump will not operate during a water heating cycle.
Radiant heating
circuit pump (P11) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. If domestic water priority is installed, the primary pump will not be powered and the IPC will not sense the call for heat until the domestic water heating cycle is completed. The IPC regulates injection pump flow rate, increasing flow to raise the supply temperature, or lowering flow to reduce it. If boiler return temperature drops below the preset limit (130 F), the IPC reduces injection flow (reducing the temperature drop in the primary circuit).
Part Number 650-000-240/1098
93
XII
P1
flow/check valve

Baseboard zones
(when above primary) Zone valves
P3
Zone valves note 2
P3
Alternate piping to circuit at left, using flow/check valve on return line in place of thermal trap
Fill
Purging valves
P3
Primary circuit
Thermal trap - 18" min. note 2
Baseboard zones
(when below primary)
Purging valves DHW outlet

flow/check valve
cold water inlet
IPC P10
Zone valves
Use minimum 18" thermal trap as alternate to flow/check valve
IPP Injection
pump panel
Purging valves Supply temperature sensor
P11
Alternate piping
P2

Manifold location A
Boiler
Cold
Manifold location B
Mixed
Hot
Figure 57 - System CP10a Radiant heating, domestic water heating and baseboard heating with conventional boiler - baseboard zoning with zone valves
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel. 4. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring for this piping alternative. Part Number 650-000-240/1098
94
Figure 58 System CP10a Schematic wiring diagram

L1
120 VAC
Reset On
Reset Off
Supply Temp.
Max. Supply Temp.
Baseboard thermostats
Zone valves
N
120 V (ac)
Supply Temp Ratio
Power
Inj Sys Pump Pump
Baseboard relay
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P3
Baseboard pump
P10
P11
Indoor sensor, Outdoor if used sensor, in lieu if used of valve actuators
DHW relay
Relay shown wired for domestic priority. Add (2) jumpers, shown in red, to remove priority.

Minimum rating 10 va plus 6 va per AlumiPex valve actuator connected, plus total va load of all zone valves connected DHW tank aquastat Primary pump
C1 C2
24 VAC
P1
DHW pump
P2
L N
Room thermostat To additional actuators Room thermostat 4-wire actuator See note 3 2-wire actuator
Oil-fired Boiler
G
B1
See note 3 Valve actuator Valve actuator Valve actuator Burner
B2
Notes
1. This drawing is conceptual only. It shows representative system wiring. Weil-McLain does not represent that this drawing meets any particular mechanical, electrical, or building codes. All wiring must be installed in accordance with: In the USA - the latest version of the National Electrical Code (N.E.C.), as well as any other National, State or Local code requirements having jurisdiction. In Canada - CSA C22.1 (C.E.C.) Part 1, as well as any other National, Provincial or Local code requirements having jurisdiction. The installer is responsible for inclusion of all required safety devices, or other miscellaneous hardware not shown on drawing. 2. The minimum wire gauge used for all low voltage circuits shall be 18 AWG unless otherwise required by code(s) having jurisdiction. 3. Multiple valve actuators may be powered through a common thermostat for rooms/zones having multiple radiant circuits. End switches are optional on all but one valve actuator wired in this manner. 4. See Weil-McLain installation instructions for specific details on installing the boiler, and injection pump panel.
Part Number 650-000-240/1098
95
XII
P1
flow/check valve

P4 P5 P6
Flow/check valves
Baseboard zones
(when above primary)
P4 P5 P6
Flow/check valves
P3
note 2
Fill
Purging valves
Primary circuit
Baseboard zones
P4 P5
Purging valves
P6
Flow/check valves
DHW outlet
flow/check valve
cold water inlet
IPC P10
IPP Injection
pump panel
P11
Alternate piping
P2

Manifold location A
Boiler
Cold
Manifold location B
Mixed
Hot
Figure 59 - System CP10b Radiant heating, domestic water heating and baseboard heating with conventional boiler - baseboard zoning with pumps
Notes 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel. 4. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring for this piping alternative.
96
Part Number 650-000-240/1098
Figure 60 System CP10b Schematic wiring diagram

L1
120 VAC
Reset On
DHW tank aquastat
Baseboard zone thermostats
Reset Off
Supply Temp.
Max. Supply Temp.
N
120 V (ac)
Supply Temp Ratio

Power Isolated boiler contact
T1 T1 T2 T2
T3 T3
T4 T4
T5 T5
T6 T6
Multi-zone relay center

See control manufacturer's instructions for DHW priority activation
Power
Inj Sys Pump Pump
T N
T T
PR PR C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 C6 C6
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2
P4
P5
P6
P10 P11
DHW pump
DHW relay - use if DHW priority reqd 120 VAC coil (supplied by installer)
P1
Primary pump

24 VAC
T
T
L
C1 C2
Room thermostat
Room thermostat
2-wire actuator
N
G B1
Valve actuator Valve actuator Burner
B2 Oil-fired Boiler
Notes
97
XII
System CP-11 Radiant heating, domestic water heating and (pages 100 103) baseboard heating with GV boiler
Purpose Provide multiple heating functions - radiant heating and baseboard heating plus domestic
water heating (with optional domestic priority). The control and injection pump regulate radiant circuit supply temperature and help maintain minimum boiler return temperature. Two versions are shown - one for baseboard zoning with zone valves (CP-11a) and the other for baseboard zoning with pumps (CP-11b).
Pumps and piping

Primary circuit
The GV integral pump provides flow in the primary circuit. If more flow is required, install
the GV boiler as a secondary circuit off the primary and provide an appropriately sized primary pump.
Radiant circuits
(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.) System CP-11 shows two manifold locations for the radiant circuits. The same piping design can be used for multiple manifolds. Manifold valve actuators are optional, but recommended as discussed in Zoning radiant heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone thermostat or a dry contact that closes on a call for heat.
heater for the supply water temperature available. Connect the water heater in the first secondary circuit off of the primary. This assures the hottest available supply water.
Baseboard circuits
The system illustration shows several options for baseboard circuit piping. Provide the pumps
needed for the baseboards. Each baseboard branch circuit off of the primary will require at least one pump, even if zoning with zone valves. Use flow/check valves in the baseboard circuits as illustrated. A flow/check is required in every loop when zoning with pumps. A flow/ check is required on the return piping when the piping is above the primary unless a thermal trap is provided as shown.
98
Part Number 650-000-240/1098
System CP-11
Controls and wiring

Baseboard and water heating controls
Baseboard heating and domestic water heating are operated through a Multi-zone relay center, illustrated based
on zoning the baseboard heating with pumps. If zoning with zone valves, replace the thermostats shown connected to the relay center with the zone valve end switches. If domestic water heating priority is desired, add the DHW relay.
An IPC (Injection Pump Control) is included with the IPP panel (or purchased separately when using field
constructed injection mixing systems). The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor). You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response. The IPC controls the injection pump (P10) and radiant circuit pump (P11). The primary pump (P1) is integral to the GV boiler (activated by the boiler controls). Use IPC dip switch 2 to set radiant circuit pump operation - DOWN for intermittent operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close. Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an indoor sensor is connected to the IPC.
Operation
On call for heat from the water heater tank aquastat, the DHW circulator is activated by the relay center and the
DHW relay (optional) is activated. If wired for domestic priority, the DHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P10). The radiant circuit pump (P11) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.
Baseboard heating
On call for heat from a baseboard zone, the relay center activates the zone pump and turns on the boiler. The
boiler, in turn, activates the primary pump (P1).
Radiant heating
circuit pump (P11) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. If domestic water priority is installed, the IPC will not sense the call for heat until the domestic water heating cycle is completed. The IPC regulates injection pump flow rate, increasing flow to raise the supply temperature, or lowering flow to reduce it. If boiler return temperature drops below the preset limit (130 F), the IPC reduces injection flow (reducing the temperature drop in the primary circuit).
Part Number 650-000-240/1098
99
XII

Baseboard zones
(when above primary) Zone valves
P3
Zone valves note 2
P3
Purging valves
P3
Primary circuit
DHW outlet
flow/check valve
Baseboard zones
cold water inlet Return temperature sensor
Purging valves
IPC P10
Zone valves
note 2
IPP Injection
pump panel
P2 GOLD Plus water heater

P11
Alternate piping


Cold
Fill
Manifold location B
Mixed
Hot
Figure 61 - System CP11a Radiant heating, domestic water heating and baseboard heating with GV boiler baseboard zoning with zone valves
Notes
100

L1
120 VAC
Reset On
Reset Off
Supply Temp.
Max. Supply Temp.
Zone valves
N
120 V (ac)
Supply Temp Ratio
Power
Inj Sys Pump Pump
Baseboard relay
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P3
Baseboard pump
P10
P11
DHW tank aquastat

Minimum rating 10 va plus 6 va per AlumiPex valve actuator connected, plus total va load of all zone valves connected Relay shown wired for domestic priority. Add jumper, shown in red, to remove priority.
24 VAC
DHW pump DHW relay
P2
Room thermostat
Room thermostat
4-wire actuator See note 3 2-wire actuator
L N GV Boiler G
P1
Integral pump
Notes
Part Number 650-000-240/1098
101
XII

P4 P5 P6
Flow/check valves
Baseboard zones
(when above primary)
P4 P5 P6
Flow/check valves
P3
note 2
Purging valves
Primary circuit
DHW outlet
flow/check valve
Baseboard zones
P4 P5
cold water inlet Return temperature sensor
Purging valves
P6
Flow/check valves
IPC P10
note 2
IPP Injection
pump panel
P2 GOLD Plus water heater

P11
Alternate piping


Cold
Fill
Manifold location B
Mixed
Hot
Figure 63 - System CP11b Radiant heating, domestic water heating and baseboard heating with GV boiler baseboard zoning with pumps
Notes
1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipe diameters long. 3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel.
102
Part Number 650-000-240/1098
Figure 64 System CP11b Schematic wiring diagram L1

120 VAC
Reset On
DHW tank aquastat
Baseboard zone thermostats
Reset Off
Supply Temp.
Max. Supply Temp.
N
120 V (ac)
Supply Temp Ratio

T1 T1 T2 T2
T3 T3
T4 T4
T5 T5
T6 T6

See control manufacturer's instructions for DHW priority activation
Power
Inj Sys Pump Pump
T N
T T
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P2
P4
P5
P6
P10 P11
DHW pump
DHW relay - use if DHW priority reqd 120 VAC coil (supplied by installer)

24 VAC
Room thermostat
Room thermostat
2-wire actuator
T L
N G GV Boiler
P1
Notes
103
XII
(p.106 109)
System Radiant heating, domestic water heating and baseboard CP-12 heating with multiple boilers
Purpose Use a multiple boiler system to provide multiple
heating functions - radiant heating and baseboard heating plus domestic water heating (with optional domestic priority). The control and injection pump regulate radiant circuit supply temperature and help maintain minimum boiler return temperature.
System CP-12 shows three manifold locations for

the radiant circuits. The same piping design can be used for multiple manifolds.
Manifold valve actuators are optional, but

recommended as discussed in Zoning radiant heating systems, section IV of this Guide. When actuators are not used, provide the call for heat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zone thermostat or a dry contact that closes on a call for heat.
This system provides domestic water heating without

flow in the primary circuit, reducing piping losses during non-heating season periods. Flow is only required in the multiple boiler secondary piping during domestic water heating cycles.
Two versions are shown - one for baseboard zoning

with zone valves (CP-12a) and the other for baseboard zoning with pumps (CP-12b).
Provide a pump with the domestic water heater, sized

to give the required flow through the heater for the supply water temperature available.
Connect the DHW as a secondary circuit directly off

of the multiple boiler supply manifold. This assures the hottest possible supply water temperature.
Baseboard circuits
Pumps and piping

Primary circuit
Provide a primary pump sized for the flow needed.

Multiple boiler circuits
The system illustration shows two options for

baseboard circuit piping (see also system CP-10 for additional options). Provide the pumps needed for the baseboards. Each baseboard branch circuit off of the primary will require at least one pump, even if zoning with zone valves. Use flow/check valves in the baseboard circuits as illustrated. A flow/check is required in every loop when zoning with pumps. A flow/check is required on the return piping when the piping is above the primary unless a thermal trap is provided as shown.
Provide a pump and flow/check valve for each boiler

(or use factory-packaged pump, if applicable).
Residential packaged boilers may have the pump

mounted on the return piping at the boiler. The pump can be used in this location provided the expansion tank or compression tank and fill line are correctly located.
Controls and wiring

Baseboard and domestic water heating controls
The Injection Pump Panel (IPP) includes the injection

pump and the radiant circuit pump. (For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPC Injection Pump Control with an injection pump and radiant circuit pump sized for the flow rates and pressure drops needed.)
Baseboard heating and domestic water heating are

operated through a Multi-zone relay center, illustrated based on zoning the baseboard heating with pumps. If zoning with zone valves, replace the
104
Part Number 650-000-240/1098
System CP-12
thermostats shown connected to the relay center with the zone valve end switches.
Radiant controls
Operation
An IPC (Injection Pump Control) is included with

the IPP panel (or purchased separately when using field-constructed injection mixing systems).
On call for heat from the water heater tank aquastat,

the DHW relay is activated. The relay activates the boiler and signals the multiple boiler control to activate the DHW pump. The multiple boiler control sequences boilers on as needed to meet the demand. If wired for domestic priority, the DHW relay turns off the primary pump (P4) and interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P12). The radiant circuit pump (P13) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.
Baseboard heating
The IPC can be set for fixed supply temperature or

outdoor reset (requires outdoor sensor). You can connect an indoor temperature sensor or tekmar zone control to the IPC to provide room temperature feedback to the control, allowing heating circuit regulation based on space temperature response.
The IPC controls the injection pump (P2) and radiant

circuit pump (P3). The primary pump (P1) operates with the boiler (activated by the boiler controls).
On call for heat from a baseboard zone, the relay

center activates the zone pump and sends a call for heat to the multiple boiler control. The multiple boiler control, in turn, activates the primary pump (P1) and sequences boilers on as needed to meet demand. If domestic water priority is installed, the primary pump will not operate during a water heating cycle.
Radiant heating
Use IPC dip switch 2 to set radiant circuit pump

operation - DOWN for intermittent operation, UP for continuous pump operation. With continuous radiant pump operation, either use no manifold valve actuators or install a differential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when the manifold valve actuators close.
Do not connect a 24 volt or 120 volt signal to terminals

15 and 16 if either a zone control or an indoor sensor is connected to the IPC.
DHW controls
On call for heat from a radiant zone thermostat or

actuator, the IPC activates its injection pump (P10), radiant circuit pump (P11) and sends a call for heat to the multiple boiler control. The multiple boiler control activates the primary pump (P1), initiating flow in the primary, and sequences boilers on as needed to meet demand. If domestic water priority is installed, the primary pump will not be powered and the IPC will not sense the call for heat until the domestic water heating cycle is completed.
Provide the DHW relay shown is domestic priority is

desired or to prevent flow in the primary piping during non-heating season domestic water heating periods.
Multiple boiler controller. Install multiple boiler control, as illustrated. The

multiple boiler control shown has provision for activation of the DHW pump on a signal from the DHW relay.
Part Number 650-000-240/1098
The IPC regulates injection pump flow rate, increasing

flow to raise the supply temperature, or lowering flow to reduce it.
If boiler return temperature drops below the preset

limit (130 F), the IPC reduces injection flow (reducing the temperature drop in the primary circuit).
105
XII
Radiant heating system examples CP12a
Baseboard zones
P5 P5
flow/check valve
note 2
Use minimum 18 thermal trap as alternate to flow/check valve
Primary circuit
System pump
P4
flow/check valve
note 2
swing check valve (to prevent heat migration)
Fill
Primary circuit return
M C H Primary circuit supply Note 2
P12
Purging valves
Expansion tank
IPP Injection pump panel
Alternate piping (using mixing valves) Substitute for IPP panel

C M H
Heating system pump Return from heating system Supply to heating system
P13
Supply temp. sensor
P3
To additional boilers
Manifold location A
DHW outlet
cold water inlet
Differential pressure by-pass valve - required if using manifold valves and continuous pump operation
PB1 Boiler
PB2
Manifold location B
Boiler
Manifold location C
Figure 65 - System CP12a Radiant heating, domestic water heating and baseboard heating with multiple boilers baseboard zoning with zone valves
Notes
106

L1
120 VAC
Reset On
Reset Off
Supply Temp.
Max. Supply Temp.
Zone valves
N
120 V (ac)
Supply Temp Ratio
Power
Inj Sys Pump Pump
Baseboard relay
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
Baseboard pump
P12 P13
P3
DHW pump
space heat demand L1 N
DHW circulator
DHW heat demand
Multiple boiler control

DHW tank aquastat
DHW priority relay Primary circulator
system circulator Boiler 2 Boiler 1
24 VAC
Relay shown wired for domestic priority. Add (2) jumpers, shown in red above, to remove priority.
P4
L N
Room thermostat Room thermostat
T
N G B1 B2
Burner
G B1 B2
4-wire actuator
See note 3
2-wire actuator Burner
C1 C2
Valve actuator Valve actuator Valve actuator
C1 C2
Boiler #2
PB2
Boiler Circulator
Boiler #1
PB1
Boiler Circulator
Notes
Part Number 650-000-240/1098
107
XII
Radiant heating system examples CP12b

P5 P5 P6 P7
flow/check valves flow/check valve
Baseboard zones
P6 P7
Alternate piping to circuit at left, using flow/check valve on return line in place of thermal trap.
note 2
Use minimum 18 thermal trap as alternate to flow/check valve
Primary circuit
System pump
P4
flow/check valve
note 2
swing check valve (to prevent heat migration)
Fill
Primary circuit return
M C H Primary circuit supply Note 2
P12
Purging valves
Expansion tank
IPP Injection pump panel
Alternate piping (using mixing valves) Substitute for IPP panel

C M H
Heating system pump Return from heating system Supply to heating system
P13
Supply temp. sensor
P3
To additional boilers
Manifold location A
DHW outlet
cold water inlet
Differential pressure by-pass valve - required if using manifold valves and continuous pump operation
PB1 Boiler
PB2
Manifold location B
Boiler
Manifold location C
Figure 67 - System CP12b Radiant heating, domestic water heating and baseboard heating with multiple boilers baseboard zoning with pumps
Notes
108
Figure 68 System CP12b Schematic wiring diagram L1

120 VAC
Reset On
Reset Off
Supply Temp.
Max. Supply Temp.
N
120 V (ac)
Supply Temp Ratio

T1 T1 T2 T2
T3 T3
T4 T4
T5 T5
T6 T6

Power
Inj Sys Pump Pump
L N
T T
Service switch
1 2
3 4 5 6
7 8 9 10
11 12 13 14
15 16 17 18
P4
P5
P6
P12
P13
P3
DHW pump
space heat demand L1 N
DHW circulator
DHW heat demand
Multiple boiler control

DHW tank aquastat
DHW priority relay Primary circulator
system circulator Boiler 2 Boiler 1
24 VAC
Relay shown wired for domestic priority. Add (2) jumpers, shown in red above, to remove priority.
P4
L N
Room thermostat Room thermostat
T
N G B1 B2
Burner
G B1 B2
4-wire actuator
See note 3
2-wire actuator Burner
C1 C2
Valve actuator Valve actuator Valve actuator
C1 C2
Boiler #2
PB2
Boiler Circulator
Boiler #1
PB1
Boiler Circulator
Notes
Part Number 650-000-240/1098
109
XIII
Appendix
Pump curve equations
To calculate the Feet head for any flow rate for the pump curves given in Figure 26, you can use the following polynomial equations. Use only for the flow rate range shown in the curves.
Taco 007 Taco 0010 Taco 0011 Taco 0012 Taco 0014 Grundfos 15-42 Grundfos 26-64 Grundfos 43-75 B & G NRF-22 B & G PL-30 B & G PL-50
Feet head = 10.932555 - 0.16875578xGPM - 0.01521757xGPM2 + 0.00020748122xGPM3
Feet head = 21.973589 - 0.48933166xGPM - 0.00063109078xGPM2 0.00011604224xGPM3
Feet head = 21.973589 - 0.48933166xGPM + 0.00063109078xGPM2 0.00011604224xGPM3
Feet head = 26.387423 - 0.41974859xGPM - 0.003483614xGPM2 + .00000606xGPM3
Feet head = 15 - 0.68182xGPM
110
Part Number 650-000-240/1098
Quick selector curve equations

The curves shown in Figures 27 through 30 can also be directly calculated using the formula and the chart below. Use only in the flow rate ranges shown in the quick selector curves.
GPM = a
TEL
TEL
Tube size a " AlumiPex b c a " AlumiPex b c a 1" AlumiPex b c a " Copper b c a 1" Copper b c a 1" Copper b c a 1 " Copper b c a 2" Copper b c
Pump model number

007 0010 0012 0014 15-42 26-64 43-75 NRF-22 PL-30 PL-50
20.977506 23.949589 26.724723 31.648593 25.160229 32.548114 36.067917 23.053464 33.244621 30.128854 0.9999193 0.9999884 0.999995 0.99998 0.9999484 0.999969 0.9999864 0.99994541 0.9999744 0.9999939
-0.546243 -0.566845 -0.568391 -0.553786 -0.539398 -0.54395 -0.558151 -0.53630256 -0.549257 -0.567042 47.282097 83.654266 98.227686 93.893487 56.91038 32.513578 115.98578 51.346672 90.532778 112.76368 0.9995437 0.999942 0.9999694 0.9999269 0.9998195 0.9999679 0.9999606 0.99979985 0.9999122 0.9999824 -0.426158 -0.539835 -0.551448 -0.505463 -0.443727 -0.543695 -0.524145 -0.43772596 -0.488098 -0.554712 75.153462 124.66566 172.66094 132.81573 44.919189 102.76405 175.50699 51.754916 106.20044 201.74157 0.9997386 0.9998432 0.9999264 0.9998754 0.9995672 0.9998416 0.9999229 0.99965195 0.9998299 0.999942 -0.396225 -0.473094 -0.515583 -0.441545 -0.274307 -0.392628 -0.471034 -0.31668162 -0.394699 -0.522198 71.379514 97.515613 112.68287 109.82208 64.567699 100.35663 131.28224 61.643267 105.56214 128.15213 0.9998936 0.9999686 0.9999806 0.9999566 0.9998539 0.9999435 0.9999674 0.99987245 0.9999436 0.9999854 -0.499304 -0.546292 -0.553938 -0.513679 -0.448395 -0.488876 -0.524849 -0.4548061 -0.496315 -0.555043 79.99001 138.55373 192.92987 154.57651 57.748169 122.83323 192.50008 64.069652 129.29073 226.29686 0.9997583 0.999878 0.9999562 0.9999245 0.9997203 0.999904 0.9999398 0.9997766 0.9998997 0.9999686 -0.39971 -0.483946 -0.526506 -0.461537 -0.320622 -0.41861 -0.478421 -0.35422024 -0.424158 -0.533449 64.967808 126.50711 228.88302 152.62247 37.056987 106.04502 204.08838 48.05632 106.69447 295.9619
0.9996432 0.9997491 0.9998911 0.9998716 0.9995942 0.9998456 0.9998984 0.99965962 0.999835 0.9999352 -0.281352 -0.376797 -0.46497 -0.380913 -0.173726 -0.321963 -0.408756 -0.23103054 -0.318881 -0.490197 58.008279 83.121812 225.94646 99.75135 27.252814 65.834312 168.76916 36.458671 59.002982 281.5639 0.9996916 0.9996014 0.9998454 0.99976 0.9996179 0.9997318 0.9998486 0.99963654 0.9997032 0.9998785
-0.214147 -0.23636 -0.394833 -0.249847 -0.084596 -0.188388 -0.318849 -0.13868336 -0.165534 -0.413095 51.44484 62.224837 113.27687 53.9907 22.343917 40.881309 61.072713 25.510536 36.801943 91.875092
0.9998399 0.9997454 0.9996836 0.9997668 0.9998137 0.9997681 0.9996566 0.99973669 0.9997716 0.9996731 -0.145029 -0.12866 -0.182626 -0.089707 -0.027987 -0.061195 -0.070971 -0.03819045 -0.044815 -0.132512
Part Number 650-000-240/1098
111
Price $20
112
Part Number 650-000-240/1098

Weil Mclain Radiant Heat

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AlumiPex

Tubing Radiant Tubing

Part No. 650-000-240/1098

AlumiPe Tubing AlumiPex Radiant Tubing

Read this page first

Codes and standards

Part Number 650-000-240/1098

Controls q Pumps q Wiring Installation Guide

Zoning radiant heating systems

Control strategies general

Injection mixing components

VII Determining flow rates

VIII Determining head loss

Piping radiant circuits ........................................................................................................... 46 Domestic water heating ....................................................................................................... 52

XII Radiant heating system examples ...................................................................................... 54

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

AlumiPe Tubing AlumiPex Radiant Tubing

Piping & control methods provides you a choice of

primary/secondary piping and some suggestions on how to apply it.

Pump Panel/Injection Pump Control (IPC) Installation and Operating Manual.

Controls q Pumps q Wiring Installation Guide

Piping & control methods

AlumiPe Tubing AlumiPex Radiant Tubing

Piping & control methods - continued

Alternative piping/controlling methods

Part Number 650-000-240/1098

Controls q Pumps q Wiring Installation Guide

Method 1 Variable speed injection mixing

Figure 1 Radiant heating Method 1 Injection mixing

Boiler loop return

Boiler loop supply

Part Number 650-000-240/1098

AlumiPe Tubing AlumiPex Radiant Tubing

Piping & control methods - continued

Pump speed is increased when the system supply

The pump is slowed as the system supply

The balancing valve in the injection circuit is used to

Figure 2 Radiant heating Method 1 Injection mixing, typical

Boiler loop pump

Injection Pump Control

System supply sensor

Heating system pump

Part Number 650-000-240/1098

Controls q Pumps q Wiring Installation Guide

Method 2 Dual mixing valves

Exception: Control of boiler return temperature should

Boiler loop pump

Mixed Cold Hot

Cold Mixed Hot Manifolds

Heating system pump

Part Number 650-000-240/1098

AlumiPe Tubing AlumiPex Radiant Tubing

Loop operations are independent

Simple isolation for service

Piping and pump sizing more efficient No by-pass pressure regulator

Multiple boiler advantages

Part Number 650-000-240/1098

Controls q Pumps q Wiring Installation Guide

Figure 4 Traditional two-pipe system, typical

Figure 6 Primary/secondary system, typical

By-pass pressure regulator

Figure 5 Two-pipe system load branch

Figure 7 Primary/secondary branch loop

AlumiPe Tubing AlumiPex Radiant Tubing