Hrhinstall

INSTALLATION INSTRUCTIONS
HYDRONIC
RADIANT
HEATING SYSTEMS
January 2004
Congratulations on the selection of Vanguard’s Vanex® PEX (cross-linked polyethylene) tubing and
components for your Hydronic Radiant Heating System installation. This installation guide is presented
to assist installers, designers and code officials in the quality installation and inspection of a Vanguard
Radiant Heating System. This installation guide relates specifically to PEX tubing and components
supplied by Vanguard Piping Systems, Inc. and is not applicable to tubing or components from other
manufacturers.
To assure the successful and quality installation of a Vanguard Hydronic Radiant Heating System, it is
important that those doing the installation read and understand this guide, fully. Since many hydronic
heating systems are literally “cast in concrete”, and must endure a very long service life, it is very
important that the PEX tubing is not damaged during installation or by further construction activity after
installation. PEX tubing is a durable product; however, nails, staples, shovels and other sharp objects
or tools can damage it. Damage that compromises the integrity of the tubing can lead to premature
failure and is costly to repair. Exercising a reasonable amount of care during the installation process and
making other trades aware of the presence of the tubing will help insure that the PEX tubing will perform
without incident for decades to come and will probably outlast the structure.
The key to the flawless performance of any radiant floor heating system relies heavily upon proper
planning. Each system must be properly designed for the particular structure and the system must be
installed in accordance with that design. A radiant floor heating system cannot cure a heating problem
in a poorly insulated or uninsulated building. Since radiant floor systems operate at relatively low
temperatures, are limited to the available floor area and are difficult to modify after installation, the
heating system must be designed to provide the required heat-load of the building or supplemental heat
must be a part of the design. This guide contains no significant heat-load design information. However,
Vanguard’s Hydronic Radiant Heating Design Software is available to assist system designers. Other,
industry accepted methods of calculating heat-load design requirements can also be employed. Do not
attempt to install a system without a proper heat-load design as it invites poor system performance and
can adversely affect the comfort level attainable by the system.
Thank you for choosing the Vanguard System.
2
SYSTEM BASICS
A hydronic radiant floor heating system is really quite
simple. Heated water is circulated through Vanex PEX
tubing installed in or under the floor of the building. As
the heated water warms the floor, it becomes a huge
radiant-heat radiator. Since radiant heat energy passes
through air readily and radiates in all directions, it warms
the human body and objects in the building without
relying on the conduction of heat by air as with forced
air systems. The warmth that is felt from the sun easily
describes the radiant heat of a floor heating system. Even
though the sun is millions of miles away, the radiant
(also referred to as infrared) heat waves pass through
those millions of miles of space and are readily absorbed
by the skin. Radiant heating systems offer increased
comfort levels while generally allowing for lower building
A RADIANT FLOOR HEATING SYSTEM USES THE HEATED FLOOR
air temperatures. PANEL TO RADIATE HEAT INTO THE HOME OR BUILDING
To provide the necessary heat output from a radiant floor system, there must be a sufficient amount of tubing
installed in or under the floor and the temperature of the heated water must be within a range that will supply the
needed output without overheating the floor. A floor that’s too warm will be as much a detriment to system comfort
as one that is too cool. A properly designed system will maintain a comfortable floor temperature while supplying
the required heat output.
A minimum hydronic radiant floor heating system includes:

1. Water heating unit of sufficient size to
meet the heat-load of the building or CIRCULATOR
space to be heated
MANIFOLDS
2. Circulation pump or pumps
3. Manifold or manifolds to distribute

the heated water to Vanex PEX tubing
loops and return the cooled water from
those loops
4. Vanex PEX tubing loops installed in HEAT SOURCE

or under the floor
PANEL
LOOPS
5. Vanex PEX supply and return tubing SIMPLIFIED RADIANT
from the hot-water source to the HEATING SYSTEM
manifold(s). SCHEMATIC
6. Thermostatic control to turn water circulation on and off as required.
Generally, additional components are also needed to assure safe and efficient operation of the system and will be
covered in detail throughout this manual.
4
SYSTEM COMPONENTS
VANEX PEX TUBING

The key to the Vanguard Radiant Heating System is Vanex PEX tubing. The flexibility and durability of Vanex PEX
offers ease of installation and extremely long service lifetime expectancy when properly installed and operated.
Vanex PEX is also available with an oxygen barrier layer. Oxygen barrier PEX (BPEX) is made available since it has
been demonstrated that hydronic heating systems that contain ferrous iron components (steel and cast iron) may
be adversely affected by the presence of too much oxygen in the water. Vanex BPEX, having a thin
layer of oxygen permeation resistant material permanently applied to the exterior of the tubing,
limits the amount of oxygen that can enter the system by permeation through the wall of
PEX tubing, substantially reducing the overall aggressiveness of the water towards
ferrous iron components. For a more detailed explanation of oxygen ingress into
radiant heating systems and its affects, see the Plastics Pipe Institute technical
paper TR-40. (PPI phone 888-314-6774 or go to www.plasticpipe.org.)
All Vanex PEX and BPEX is manufactured, tested and third-party listed to meet or exceed the requirements of ASTM
(American Standards for Testing and Materials) F 876 and F 877, and CSA (Canadian Standards Association) B137.5.
Additionally, both Vanex PEX and BPEX are certified for potable water use and BPEX meets the requirements of
German DIN Standard 4726 for oxygen permeation resistance.
TEMPERATURE & ASTM INCREMENTAL

MANUFACTURER TUBE SIZE PRESSURE RATINGS SPECIFICATIONS TUBING CLASS FOOTAGE
VANGUARD VANEX® BPEX 1/2” CTS-OD OXYGEN BARRIER TUBING 100 PSI@180 F [ NSF-pw ASTM F-876/F-877] CAN B137.5 L23707 ICBO ES ER-5287 PEX SDR-9 .070 2/28/02 CB 298
TRADE NAME TUBING TYPE POTABLE WATER ADDITIONAL THIRD DATE CODE
CERTIFICATION PARTY LISTINGS
VANEX HYDRONIC HEATING MANIFOLDS

Vanguard offers three separate lines of supply/return manifolds for hydronic
heating systems. System size, control features and economics represent the
primary differences between the separate offerings. See the Vanguard Piping
Systems Product Catalog for a complete listing of the different manifolds and
features.
Copper Manifolds
The size of the system and the desired
amount of control for separate zones
and/or individual loops will govern the
type of manifold and available manifold
control options. Very small systems having
only one to a few loops may not require a
manifold.
Comap Manifolds Simplex Manifolds

5
SYSTEM COMPONENTS
VANEX PEX TUBING FOR SUPPLY AND RETURN PIPING

Larger size Vanex PEX tubing (3/4" and 1") is used for the supply and return piping
from the water-heating unit to and from the manifolds. This tubing is also available as
BPEX with an oxygen barrier for maximum control of oxygen ingress into the system.
However, with relatively short supply/return piping runs, the advantage of oxygen
barrier tubing for supply/return piping runs is limited. It should be noted however, that some
boiler manufacturers, in order to meet warranty requirements, require that all of the tubing in a system be oxygen
barrier. Consult with the water heating unit manufacturer for their recommendation.
VANEX CRIMPSERT® FITTING SYSTEM

The Vanguard CRIMPSERT fitting system is used to make
transition connections at the water-heating unit and at the
manifolds. Vanguard offers an extensive line of CRIMPSERT
fittings to make transition connections to all types of water
heating units as well as directional changes when required.
Consult the Vanguard Piping Systems Product Catalog for a
complete listing of available fittings, crimp rings and crimp
tools.
SYSTEM CONTROLS
Vanguard offers an extensive line of radiant heating system
controls. Every radiant floor heating system requires some
form of control for comfortable and efficient operation. More
complex systems, requiring multiple water temperatures and/
or remote on/off control of manifolds or individual loops, will require additional
control elements to insure that all heated areas, regardless of heat load demand
differences, are properly heated.
BOILERS, PUMPS AND OTHER SYSTEM COMPONENTS

Vanguard does not supply boilers, circulation pumps and other system components (such as expansion tanks and
air eliminators). These components are commonly available at wholesalers that supply the hydronic heating market.
It is important in selecting components to choose those that are made specifically for hydronic heating systems and
are of the correct size for the particular system.
6
DEFINITIONS
These are terms used throughout this manual that are specific to hydronic radiant floor heating systems.
Circulator - A pump designed to circulate fluid through a hydronic heating system. These pumps
are generally fractional horsepower and low pressure but large-scale systems may require pumps of
considerable size and output.
Downward Loss - The amount of heat energy transmitted downward from a radiant floor that is not
available to heat the living space.
Edge Insulation - Insulation covering the thickness of the slab edges that are exposed or nearest the
outside wall and extending into the ground and preferably to at least the prevailing frost line.
Expansion Tank - A tank having a flexible, internal bladder that can be charged with compressed air
to compensate for volumetric changes of the fluid in a radiant heating system due to expansion and
contraction caused by temperature fluctuations of the water.
Head Loss - The pressure, expressed as feet of head, lost to friction as the result of flowing water
(or water/antifreeze mix) through system components. The total head loss for a zone is additive of
the losses through each component in the flow stream based on the amount of flow through each
component. Multiple loops on a common manifold are not additive. Only the loss through the longest
loop is used.
Injection Mixing - A method of providing temperature-controlled supply water by injecting high-

temperature water from the water-heating unit into the cooled, return water from the heating zones.
Loop - A single, continuous loop of tubing in a radiant panel.
Perimeter Insulation - Insulation placed under a slab around its perimeter from the edge of the slab 4
feet in towards its center.
Radiant Floor Panel - A heated area of floor used as a radiant heat source.
Thermostatic Mixing Valve (TMV)- A valve that mixes high-temperature water from the water heating
unit with cooled, return water from the heating zones to provide a set supply water temperature. A TMV
can be manually set or automatically controlled.
Zone - a loop or group of loops controlled by a single thermostat.
7
BEFORE YOU BEGIN
BEFORE STARTING INSTALLATION OF A VANGUARD HYDRONIC RADIANT
HEATING SYSTEM, READ, UNDERSTAND AND FOLLOW THESE CAUTIONS:
◆ Vanex PEX or BPEX must not be exposed to direct sunlight for long periods
of time. If the tubing is to be stored outdoors, it must be covered to
protect it from direct sunlight. For cast-in-slab systems where the tubing
will not be protected from direct sunlight during installation, PEX or BPEX
tubing must be covered with concrete shortly after laying the loops. The
tubing must be covered within 2 weeks or it must otherwise be protected
from sunlight exposure. Tubing tails left out of the slab for connection
to manifolds must also be protected from sunlight exposure. Too much
exposure to direct sunlight will cause tubing embrittlement, loss of long-
term stabilization and will lead to premature failure.
◆ Pressure test the system before pouring the concrete or other

topping material. The PEX tubing loops must be pressure
tested before being permanently cast into the floor material.
Also, leave a lower pressure on the loops while pouring to
expose any leaks that might happen during the pour. (See
page 28 for further information on system testing.)
◆ DO NOT use tubing that is damaged. DO NOT connect shorter

lengths of tubing together to make longer loops. Unless damaged during topping pour, there should
be no joints in the floor loops. It must always be the policy to use only continuous lengths of PEX
tubing for floor loops. (See appendix D for repair of loops damaged during the pour.)
◆ Inform the other trades working on the same structure of the

floor loops. Common damage to PEX tubing loops is from
staples, nails, screws, or other sharp fasteners. Informing the
other trades of the presence of the loops may help prevent
damage.
◆ Follow the guidelines for attaching the PEX tubing.

Fasteners that are too tight or that have sharp edges can
cause damage to the tubing over time and can lead to
premature failure.
8
BEFORE YOU BEGIN
◆ DO NOT fill the system with water if there is any possibility
that freezing conditions might occur. If the system is filled with
plain water (no antifreeze), and freezing temperatures are
encountered, the tubing will likely burst at expansion joints SYSTEM MUST
or at naturally occurring voids in the concrete. While PEX BE PROTECTED IF
32°F FREEZING
tubing out of the slab is not prone to freeze damage, tubing
encased in concrete will likely burst from the expansion of the TEMPERATURES
water as it turns to ice. The resulting pressure increase inside ARE POSSIBLE
the tubing will seek a point of least resistance and burst the
tubing at that point. Substantial slab damage can also result.
ADDITIONAL CONSIDERATIONS BEFORE STARTING
◆ Do you have details for loop spacing and lengths for each room or zone? For the system to operate
properly, an accurate room-by-room heat-loss must be done to calculate loop spacing, loop lengths
and water temperature(s). Installing a system without first performing a heat-loss evaluation of the
structure is an invitation to poor and/or inefficient system operation.
◆ All floor coverings must be considered for the system to operate properly. It must be understood
that certain changes in the floor covering can adversely affect system function and efficiency. Carpet
pad type and thickness, carpet type and pile height, the thickness of coverings such as stone or
marble can all affect system output and may require closer loop spacing or higher delivered water
temperature. The system designer must be made aware of any changes to floor coverings before
placing PEX loop tubing.
◆ Laying of PEX tubing loops and pouring of regular or thin slab should be coordinated with the other
trades working in the same structure. Once you start laying out potentially thousands of feet of PEX
tubing in a structure it is important that other trades are not walking on and working over the tubes.
This is an invitation for damage and may result in leaks if the damage is not found and repaired prior
to covering the tubing. The placement and covering of radiant loops must be coordinated with other
trades to minimize, to the greatest extent possible, damage to the tubing prior to and after the slab
pour.
◆ When considering thin-slab, it is important to locate an applicator. Since thin-slab is a relatively new
and specialized application, there are generally only a few, if any, applicators in various regions of the
country. Therefore, we recommend you locate an applicator prior to placing PEX loop tubing.
◆ Since radiant systems use a substantial amount of Vanex PEX tubing, it is important to arrange with
the wholesaler to have the required amount of tubing on hand when you need it. Wholesalers that
don’t generally serve the hydronic heating industry may not have the type, size and quantity of Vanex
PEX on hand when you’re ready to starting laying out loops. It is important to plan the number and
size of tubing coils as well as manifolds, fittings, ties, and tools and to convey those needs to the
wholesaler in advance so that the materials will be available. Vanguard’s Hydronic Heating Software
will prepare a list of materials complete with part numbers.
9
PEX TUBING LOOPS
LAYOUT BASICS
Each radiant floor panel will contain one or more loops of Vanex
PEX tubing through which the heated water is circulated. To ensure
proper heat output from the panel the loops must be laid out in a
specific pattern and attached at specific intervals. Also, the length
of individual loops must not be too long. The system design will
specify the number, length and spacing of loops. Loops that are
too long will experience higher than necessary head-loss and
temperature drop and will lead to poor system performance.
For panels with more than one loop, the length of individual loops
within the panel should be within 10% to prevent inconsistent
heat output. Even though individual loops connected to the same
manifold can be adjusted at the manifold with built-in balancing
valves, it is better to have consistent loop lengths as balancing
individual loops can be a tedious trial and error task unless individual
flow meters are used on each loop increasing system cost.
Maximum loop lengths for the different sizes of PEX tubing are
shown in the chart on the right, however, the panel design should
dictate the actual lengths used for any particular radiant panel.
Typical loop spacing is 4" to 15" and is dependent on the location of

the loops within the room and the required heat output of the radiant panel. Loops spaced too far apart
will lead to cold spots between the loops and can also require higher supply water temperatures and
will lower panel output.
85° 83° 85° 105° 80° 105°
120° 120° 140° 140°
RIGHT WRONG
LOOPS SPACED TOO FAR APART LEAD TO HOT AND COLD SPOTS AND POOR PERFORMANCE.
THE SPACING DICTATED BY THE SYSTEM DESIGN MUST BE FOLLOWED.
Each size of Vanex PEX used in radiant floor loops has a minimum bend radius dimension. When the
loops are spaced closer together than the minimum bend radius X 2, then 180° turns in the tubing
need to be swept out to the minimum dimension as shown below.
X Dimension X
Tubing Size With the Coil
3
/8" 8"
1
/2" 10"
5
/8" 12"
X
3
/4" 14"
FOR LOOP SPACING LESS THAN “X”, SWEEP 1" 18"
THE TUBING AS SHOWN
10
PEX TUBING LOOPS
To minimize waste, select coil lengths based on the required loop lengths. Vanguard makes Vanex PEX
tubing available in numerous coil lengths and, while there may not be a coil length that matches each
required loop length, a longer coil can be cut into several loops as needed. A little planning before
ordering loop tubing can result in substantially reduced tubing waste.
The Vanguard Radiant Heating Design Software automatically selects the best coil lengths for each
system layout.
Always mark both ends of each tubing loop during placement. The
marking must indicate which end is the send and which is return and it
should also be marked with some form of loop number or other identifier
when numerous loops are connected to the same manifold. A permanent
marker (such as Sharpie® or Marks-a-lot®) is usually sufficient or a flag
of tape can be attached to the portion that will be trimmed off when
connected to the manifold. This is an important step and is critical if the
manifolds will not be placed immediately.
Alternately, the loops can be connected to the manifold immediately but

the loops must still be identified as to manifold position for balancing and
other adjustments.
Individual Vanex PEX tubing loops must always be run in a continuous ALL PEX TUBING LOOPS
MUST BE IDENTIFIED FOR
length from the manifold, through the layout and back to the manifold. CONNECTION, PURGING
This is especially important for systems where the tubing will be cast into AND BALANCING
concrete or other material. DO NOT connect shorter lengths of tubing
together to make up needed loop lengths. Some connections are
allowed in systems where the tubing is not “cast-in”, however, fittings
in the loops must be kept to a minimum.
If the manifolds have not been placed prior to installation of the

loops, the ends of the loops can be connected together temporarily
to facilitate pressure testing. The figure to the right shows one
method of connection the loops so that they can be pressure tested
together. When doing this, ensure that there is sufficient tubing to
PEX TUBING LOOPS MUST BE PRESSURE
make manifold connections after the temporary fittings are cut out. TESTED BEFORE POURING SLAB. A LOWER
PRESSURE SHOULD BE MAINTAINED ON THE
SYSTEM DURING THE POUR.
WARNING! Excessive sunlight exposure will damage

PEX tubing! If the loop ends protruding from the slab
will not be shielded from direct sunlight within 2 weeks
of tubing installation they must be protected from sunlight
exposure. Wrap the tubing with black plastic or otherwise cover
it to completely shield the tubing from sunlight. Failure to do
this will result in premature tubing failure.
11
PEX TUBING LOOPS
SINGLE SERPENTINE DOUBLE SERPENTINE
Outside Wall Outside Wall
Outside Wall
SINGLE SERPENTINE
WITH PERIMETER BANDING TRIPLE SERPENTINE
Outside Wall Outside Wall
Outside Wall
Outside Wall
Each radiant panel requires a layout that is specific to the
space being heated. The illustrations below show the most
common loop layouts but these may need to be modified
for some rooms.
The rule is that the supply side of each loop (with the
hottest water) is installed towards the exterior wall or walls
and the cooler part of the loop (as it is returning to the
manifold), is installed towards the room’s center or interior
walls. The design may also require closer spacing near
the outside walls, commonly called perimeter banding, to
account for higher heat loss.
For rooms with no exterior wall, it is recommended to use

the counter-flow spiral pattern to provide the most even heating.
At high radiant panel heat-loads, loop lengths, loop spacing and layout become more critical. Please
remember that modifying a layout once the floor covering has been placed is nearly impossible without
completely destroying the floor and starting over. It is better to plan ahead to prevent potential problems.
12
TYPES OF FLOOR CONSTRUCTION
SLAB
Slab construction is well suited to radiant floor heating since the
warmed concrete becomes a huge thermal mass. For most
slab applications, the tubing is tied to the re-mesh or re-bar
reinforcement with zip-ties (Vanguard part #HRCT) or re-bar
twist ties. When using re-bar twist ties they must not be twisted
too tight possibly damaging the PEX tubing. Once the concrete
is poured over the tubing, the ties no longer serve an anchoring
function so they need not be installed overly tight.
Tie the tubing to the re-bar or re-mesh every 3-4 feet

along straight runs. At 90° turns, tie the tubing within 12" on each
side of the turn. For turns greater than 90°, tie the tubing within 12"
on each side of the turn and in the middle of the arc to prevent the
tubing from moving or floating to the top during the concrete pour.
(See figure at left.)
Keep the PEX tubing at least 6" away from slab penetrations, block-
outs or other similar structural embedments. Unless local building
code does not allow it, a vapor barrier (such as 6 mil polyethylene
sheeting or equivalent) should be installed under the entire slab.
LOOP TUBES ARE ATTACHED TO RE-MESH (SEE TEXT)
Install only continuous loops of tubing into the slab. Starting at the manifold location and leaving sufficient tubing
to make the manifold connections, run each loop continuously through the loop layout and back to the manifold
location. DO NOT connect several shorter lengths of tubing together the make a complete loop. Vanguard supplies
Vanex PEX in numerous coil lengths to minimize waste. To provide for a cost-effective installation, order coil lengths
that are either close to the required loop lengths or that can be cut into lengths that will minimize the length of
“tails” to be cut off.
Run continuous lengths of Vanex pex through the loop layout and
back to the manifold location. Use HRSL3 or HRSL4 plastic elbows
or HRCSL3 or HRCSL4 corrugated sleeving where the tubing enters
the slab. Elbows or sleeving can be tied to re-bar supports as
shown. Cut re-bar off flush with concrete when cured.
Elbows or sleeving may

be tied on alternate sides
of support to provide
better line-up with mani-
folds.
13
Ideally, the PEX tubing loops should be placed about 2 inches below the top
surface of the slab. This is usually accomplished by installing risers that hold the
re-bar or re-mesh at a constant height, or during the concrete pour, by hand
pulling the reinforcement (with PEX tubing attached) to the desired level.
NOTE: All fill material below a radiant slab must be free of sharp objects that can
damage the Vanex PEX tubing. If gravel is specified for under-slab fill, it must not have sharp edges.
Smooth pea gravel is recommended.
CAUTION! DO NOT drill into or drive fasteners into the slab

as you can puncture the PEX tubing causing a leak. Make
the other construction trades aware of the presence of the
tubing to minimize the risk of this type of damage as it is difficult and
costly to repair. If the slab must be penetrated, the tubing loops must
be accurately located to prevent damage.
INSULATION
Exposed slab edges must be insulated for efficient system operation. The most common edge insulation
is 1 to 2 inch in thick, closed-cell Styrofoam extending down to at least the prevailing frost line. The
system design should specify the type and thickness of edge insulation.
If edge insulation to the prevailing frost line is impossible or impractical, at the very least, edge insulation
should fully cover the exposed slab edge and extend into the ground at least a few inches. Remember
if the design specifies edge insulation to the frost line and that recommendation is not followed, the
slab will experience higher edge heat loss, may not perform properly and system efficiency will suffer.
In extreme cases, failure to install edge insulation where the system
design calls for it could result in enough additional heat loss to overrun
the boiler output.
When attaching insulation to the slab forms prior to pouring, adjust

the form position outward the
thickness of the insulation so
that the outer wall does not sit
partially on the insulation.
14
When setting insulation prior
to pouring a mono-pour slab/
foundation, adjust the width of
the trench and the placement
of the forms to accommodate
the additional thickness of the
insulation so that the outer wall
does not sit on the insulation.
Perimeter insulation is also TO FROST

recommended to promote LINE
efficient operation and to
minimize heat loss. Perimeter
insulation should extend a
minimum of 4 feet inward from
the outside slab edges and be
ADJUST FOR
installed around the entire outside INSULATION
perimeter of the slab. THICKNESS
Edge and perimeter insulation will

minimize the majority of heat loss;
however, certain conditions may
require full under-slab insulation
to further minimize downward
heat loss. Those conditions
include high water table, high
slab heat-load, and high R-value
floor coverings. If there is a
question as to the need for full TO FROST
under-slab insulation, consult the LINE
system design and/or the system
engineer. 4 FT. OR PER
DESIGN
The top of exposed edge

insulation should be
angled to provide water
run-off and should be
covered with flashing
or other metal trim to
prevent degradation of
the foam.
15
When using full underslab insulation and securing the PEX loop
tubing directly to the foam insulation, the R-value of the cover-
ing over the tubing increases and system response and required FOR
water temperature will be affected. An increase in the thickness COVER
of covering over loop tubing results in higher required water > 2”
temperature and can cause sluggish system response to chang-
ing heat loads. The system control type or control parameters
may require adjustment to accommodate the delay in system COVERING THICKNESS > 2” OVER LOOP TUBING
response time. RESULTS IN HIGHER WATER TEMPERATURES AND
CAN CAUSE SLUGGISH RESPONSE
If fastening the PEX tubing directly to the foam insulation, see

Over an Existing Slab for fastening instructions.
In some rare instances, the PEX tubing must be placed in the

sand backfill below the slab. Use caution with this method
as system response time and required water temperature is
significantly affected. Also, water temperature must not exceed
DO NOT PLACE PEX TUBING LOOPS IN THE
140° F to prevent crystallization of the sand which leads to very
SAND BED BELOW A SLAB UNLESS THE DE-
poor heat transfer. Do not place the tubing in the sand below SIGN SPECIFIES IT
the slab unless the system design specifies it directly.
PEX tubing must be sleeved at all expansion joints and every point where it enters, exits or
penetrates the slab. For expansion joints that are to be cut, the tubing must be dipped below the
slab to prevent damage.
Plastic Turnout:
HRCSL3 OR HRCSL4 HRSL3 or HRSL4
Plastic Snap-on Sleeve:
HRCSL3 or HRCSL4
SLEEVE PEX TUBING AT ALL EXPANSION JOINTS WITH HRCSL3 OR HRCSL4
SLEEVE EVERY POINT

WHERE THE PEX TUBING
ENTERS OR EXITS CON-
CRETE. USE HRSL3 OR
HRSL4 ELBOWS OR HRCSL3
OR HRCSL4 SLEEVING
FOR CUT EXPANSION JOINTS, DIP THE TUBING BELOW THE SLAB TO A SAFE DISTANCE AT
THE CUT LINES
16
OVER AN EXISTING SLAB

For existing or new applications, a new slab can be installed
over an existing one to provide for a radiant heating panel.
Insulation should be installed between the new and
existing slabs (1” minimum recommended) that helps drive
the heat upwards and insures that the system reacts properly
to changes in the temperature of the living space. This is very
important when coverings such as carpet and pad are used
over the new slab. If insulation between the slabs is omitted,
the thermal mass increases substantially and the system will be
sluggish in responding to changes in room temperture.
NOTE: Omission of insulation between
the new slab and the old slab will sub-
For the most part, a slab over slab is installed like a Slab system stantially increase the thermal mass,
except that the new slab, since itis generally only about 2 inches making response times very sluggish.
thick, may not contain steel reinforcement and the tubing loops
may be attached directly to the insulation with the methods
described in this section. Please note, if the thickness of the Pour a
new slab over the tubing will be substantially more than 2”, the minimum 3/4"
system design must be consulted. Too much slab thickness of 3/4” slab
over the tubing will cause sluggish response to changes in room thickness
temperature. over the
loop tubing. (See text)
When installing the tubing in a poured slab over an existing slab,
the tubing can be anchored by:
WHEN USING STAP1 OR

1. Attaching to re-mesh or re-bar laid over the existing
STAP2 STAPLES, DOUBLE
slab as described in the Slab installation section. STAPLE ON BOTH SIDES
OF EACH TURN AND
SINGLE STAPLE IN THE
MIDDLE OF THE ARC
2. Attaching directly to the insulation with staples FOR TURNS GREATER
(Vanguard Part No. STAP1 and STAP2) or screw-in clips THAN 90°.
(Vanguard Part No. CLC3).
.
3. Attaching Snap-Trak (Vanguard Part No. CLMR3 or CLMR4) to the insulation
with fasteners or adhesive and snapping the Vanex PEX tubing into the
provided slots as shown in the illustration to the right.
The remaining instructions for a slab over an existing slab follow those for a Slab installation on pages 13
through 16. However since insulation between the new and existing slabs is recommended, and the new
slab will likely be only about 2” thick, then the tubing can be fastened directly to insulation laid over the entire
surface of the existing slab. Attach the tubing to the insulation with foam staples (Vanguard Part No. STAP1 or
STAP2), screw-in tubing clips (Vanguard Part No. CLC3 for 1/2” only) or install CLMR3 or CLMR4 Snap-Trak to
the insulation and snap the tubing into the supplied slots. The distance between tubing fasteners shall be the
same as shown in the Slab installation section.
17
POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR

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

poured underlayment/thin slab. Starting at the
Subfloor manifold location and leaving sufficient tubing to
make the manifold connections run each loop
continuously through the loop layout and back to the
WHEN USING STAP1 OR
STAP2 STAPLES, DOUBLE
manifold location. DO NOT connect several shorter
STAPLE ON BOTH SIDES lengths of tubing together the make a complete
OF EACH TURN AND loop. Vanguard supplies Vanex PEX in numerous coil
SINGLE STAPLE IN THE
MIDDLE OF THE ARC
lengths to minimize waste. To provide for a cost-
FOR TURNS GREATER effective installation, order coil lengths that are either
THAN 90°. close to the required loop lengths or that can be cut
into lengths that will minimize the length of “tails” to
be cut off.
There must be at least 3/4" of poured underlayment/thin 3/4"

slab over the top of the tubing.
Do not drill or
drive fasteners
into the poured
floor as you can
puncture the tubing
causing a leak. Inform the CORRECT INCORRECT
other construction trades of STAPLES MUST NOT BE DRIVEN TOO
the presence of the tubing to DEEP AND DEFORM THE TUBE. THERE
WILL BE A SLIGHT AMOUNT OF PLAY
minimize the risk of damage BETWEEN THE TUBING AND THE
during further construction. STAPLE WHEN PROPERLY DRIVEN.
18
If interior walls are to be set on the poured
underlayment/thin slab, keep the PEX tubing at least 3"
away from wall locations. Before laying out the tubing
loops, mark out the wall locations on the sub-floor to
insure accurate placement.
The joist spaces below the heated floor must be 3”

insulated. If the floor is over an unheated space, install a
minimum R19 insulation. Foil faced insulation is preferred
and the foil face is installed towards the heated side. MARK WALL LOCATIONS ON THE SUBFLOOR AND
If the space below is heated, install a minimum R11 KEEP PEX TUBING LOOPS AT LEAST 3 INCHES AWAY
FROM THEM.
insulation. As a general rule, the R-value of insulation
below a suspended panel should be at least 4 times the
R-value of the material covering the tubing (including the
poured material and any floor coverings).
NOTE! Insulating below a radiant floor

panel is important even when the space
below it is heated. The insulation “drives”
the heat upwards since radiant heat emits
FOIL FACING OR
from both sides of the heated panel. If no RADIANT BARRIER
insulation is installed, the panel will emit
radiant energy equally in both directions INSULATION - R11
TO R19 (SEE TEXT)
and the space above the floor will not be
heated properly. Foil faced insulation or a
separate radiant barrier can significantly
improve insulation performance since it reflects
infrared waves directly.
NOTE! Install plastic elbows (HRSL3 or

HRSL4) or sleeving (HRCSL3 or HRC-
SL4) to direct the tubing loops up to
the manifolds. A 1x4 installed between
studs provides a surface to clamp to.
Staple or clamp tubing to sub-floor
every 3-4 feet along straight runs and
within 12 inches on each side of turns
and in the middle of the arc for turns
greater than 90°.
19
POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR

WITH SLEEPERS (OR NAILERS) Thin Slab
When the finished floor over the heated panel requires
nailing (such as hardwood), 2x2 sleepers are installed Sleeper
between the tubing runs and the underlayment/thin slab is
poured over the tubing and screed level with the sleepers.
Other than the attachment of sleepers to the sub-floor,

installation of this type of panel is identical to the Poured
Underlayment/Thin Slab Over Suspended Floor.
Insulation
Subfloor
Leave sufficient space between sleeper ends to make turns and

supply/return runs to and from manifolds
Insulation of a thin-slab with

sleepers floor is identical to FOIL FACING OR
RADIANT BARRIER
thin/slab without sleepers.
(See page 19 for details.) INSULATION - R11
TO R19 (SEE TEXT)
20
INSTALLATION BELOW THE SUB-FLOOR Subfloor
Heat Emission
Vanex PEX tubing is installed under the sub-floor using Plates
the Vanguard Part No. HRTP3 Heat Emission Plate.
Normally, two tubes will be installed into each joist
space but check the system design, as some will only
require one. The heat emission plates are used to
fasten the tubing against the underside of the sub-floor
and help distribute the heat more evenly.
Insulation
The illustration above shows the most common method of pulling

the PEX tubing through holes drilled through the joists and into the
joist spaces. After sufficient tubing has been pulled into all of the joist
spaces, attach the tubing by nailing, stapling or screwing the heat
emission plates to the underside of the sub-floor with shingle nails,
staples or screws. Fasten each plate every 4-6 inches along each side
of tubing-groove placing fasteners about 1/2” away from each side of
the groove as shown in the figure at right.
21
Holes through joists for tubing bundles must be sufficiently sized

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

not be too long as they can
protrude through the finished
floor. Be aware of the thickness
of the flooring and use the appropriate WRONG RIGHT
length fasteners.
FOIL FACE OR RADIANT BARRIER

Install insulation in the joist cavity below the PEX loops leaving
a 1 to 2 inch air gap. A foil faced insulation or a separate radi- 1-2”
ant barrier will improve heat flow towards the heated space.
For floors over unheated spaces, install as much insulation as AIR
practical but at least R19. Insulate even if the floor is over a GAP
heated space with R11 to drive the heat upwards.
R11 MINIMUM OVER HEATED

SPACE, R19 MINIMUM OVER
UNHEATED SPACE
22
MANIFOLD LOCATION
Since most whole-house radiant heating systems will require numerous
tubing loops and at least one radiant manifold, consideration must be
given to the location of the manifold or manifolds in relation to the water
heating unit and the heating zones served by each. Some systems also
require more than one delivered water temperature and may also require
remote on/off control of one or more manifolds or even of individual
loops.
For systems requiring more than one delivered water temperature,

separate manifolds are required for each water temperature. Of course,
with very large residential or commercial systems there may be multiple
manifolds for each delivered water temperature.
It is not required to install manifolds in a dedicated space such as the

mechanical room. While that arrangement may work for some systems,
there are many times when the manifold(s) will be installed throughout RADIANT MANIFOLDS CAN BE
the structure in accessible but unobtrusive locations such as in a closet, MOUNTED WITHIN A 2X6 WALL CAV-
ITY BEHIND A DOOR OR REMOV-
a wall or under a cabinet. Manifolds can be covered with a simple duct ABLE COVER.
grate or more elaborate cover. They must, however, remain accessible
and must not be permanently concealed behind Sheetrock or plaster.
NOTE: Mounting the manifolds near the area they are intended to serve will more accurately heat
those areas and be a more efficient use of the tubing. It also reduces the risk of unintentionally over
heating a supply and return tubing pathway from the manifold to the area it is serving, such as a
hallway leading to several remote rooms.
RADIANT
MANIFOLD
LOCATIONS
SOME SYSTEMS REQUIRE THAT RADIANT MANIFOLDS BE INSTALLED IN SEPARATE LOCATIONS.

3/4” OR 1” VANEX PEX IS USED AS SUPPLY/RETURN TUBING TO THE REMOTE MANIFOLD(S).
23
MANIFOLD CONNECTIONS
RADIANT MANIFOLDS
Vanguard offers several lines of send/return manifolds specifically for hydronic radiant heating systems.
While each manifold type serves the same essential function, there are distinctions that make them
more or less applicable to some applications.
COMAP MANIFOLDS
Air Vent Manifold Con-
The Comap line of radiant manifolds is a modular nection with Manifold Isola-
Temperature tion Valve with
system that consists of an end connection kit, a 1” FPT Connec-
Gauge
send module, a return module and the loop fitting. Wireform tion
The manifold is field assembled by connecting the Module
Connector
required number of send and return modules with an
end connection kit. Any manifold from 2 to 12 ports
can be constructed from the modular components.
Changes to the number of loops can be done quickly
simply by inserting or removing send/return modules.
Send and Return Module
(Black Knob - Send)
The end connection kit features manifold isolation Termination Fitting with (Orange Knob - Return)
valves, air vents and thermometers and includes Fill Purge Connection
mounting brackets to attach the manifolds. The main
inlet/outlet connection to manifold supply tubing is 1"
female NPT.
The send and return modules look identical but are Wireform Return Module
distinguished by the color of the adjustment knob. Module with Flow Meter
The send (or supply) module (HRCMSM) has a black Connector
adjustment knob and the return module (HRCMRM)
has an orange adjustment knob. Also available is a Euro Style
return module with a built-in flow meter (HRCMFLM) Compression
so that adjustments in the flow of individual loops can Crimpsert Loop Fitting Fitting
(requires crimp ring)
be visually monitored.
Loop connections are available in Euro-compression

(1/2" and 5/8") that require only a wrench to
connect and CRIMPSERT (1/2" and 3/4") that use the
standard PEX black-copper crimp rings and crimping
tools.
HRLA24V Mounted
For systems requiring on/off control of individual on Return Module
for Individual Loop
loops, the HRLA24V loop actuator mounts directly on Actuation
the return module and also provides an end switch to
Wireform
activate other system control functions. For each loop Module
using a loop actuator, balancing is done through the Connector
built-in valve on the supply module.
24
SIMPLEX MANIFOLDS
The Simplex line of radiant manifolds is a
modular system that consists of an end
connection kit, a supply module, a return
Optional Air Vent
module and the loop fitting. The manifold is (HRSMAV)
Manifold Connector
field assembled by connecting the required with 1” FPT Connection
number of supply and return modules with an Recommended Mani-
end connection kit. Any manifold from 2 to 12 fold Isolation Valve
(not included with
ports can be constructed from the modular Termination Fitting with manifold)
components. Changes to the number of loops Fill Purge Connection
can be done quickly simply by inserting or
removing supply/return modules.
The end connection kit features a 1" female NPT

for manifold supply connections, port to install
the optional air vent (HRSMAV), fill/drain port Return Module
and includes mounting brackets to attach the (Black Plastic Cap)
manifolds.
Lock Ring
The supply and return modules look similar but
are distinguished by the fact that the supply Send Module
module (HRSMSM) has a brass cover over the (Brass Cap)
isolation valve and the return module (HRSMRM)
has a black plastic adjustment knob. Also
available is a return module with a built-in flow
meter (HRSMFLM) so that adjustments in the Return Module with
Flow Meter
flow of individual loops can be visually monitored.
Loop connections are available in Euro-

compression (1/2" and 5/8") that require only
a wrench to connect and Crimpsert (1/2" and Euro Style Com-
3/4") that use the standard PEX black-copper pression Fitting
Crimpsert Loop Fitting
crimp rings and crimping tools. (requires crimp ring)
For systems requiring on/off control of individual

loops, the HRLA24V loop actuator mounts
directly on the return module and also provides
an end switch to activate other system control
functions. For each loop using an actuator,
HRLA24V Mounted
balancing is done through the built-in valve on on Return Module
the supply module for that loop. for Individual Loop
Actuation
25
COPPER MANIFOLDS
The copper manifold line is available for those systems that require a minimum of zone and/or loop control.
They are offered with Crimpsert connections on the inlet/outlet and loop connections for systems that require
no loop isolation or balancing function and as buildup models that require the installer to join the manifold
body, inlet/outlet fittings and loop valves by sweat soldering the components together.
The Crimpsert copper manifolds are best used where all of the loops connected to a manifold pair are
identical in length (maximum 10% variation) and will provide the most equal loop-to-loop flow-rate
when connected in a reverse-return configuration (first in is last out and last in is first out). This method
yields the most consistent pressure drop through all loops connected to the same manifold pair. No
more than 12 loop tubes should be connected to a single manifold pair.
The buildup models feature isolation valves and balancing valves for individual
loop balancing control. Loop balancing is required when the length of loops
connected to a single manifold pair vary by more than 10% and/or one or
more loops connected to a manifold pair are used to heat non-contiguous
areas. Loop balancing is also required for rooms with higher heat loads at
outside walls (due to a large window area or outside door(s)), or when more
than one room is served by a manifold pair, especially when each room has a
significantly different heat load requirement.
Loop isolation and Crimpsert Copper Manifolds

balancing valves are
available with either Closed-end Model
Crimpsert loop connec-
tions (assembled with
black copper crimp rings
and crimp tools) or with
Flow-through Model
compression fittings that
require only a wrench to
connect.
Buildup Manifolds Crimp rings

required for
Crimpsert
Connections
Crimpsert
Transition Crimpsert
Fitting Isolation and
Balancing Valves
Copper Manifolds
Shown Mounted in
Euro Compression Crimp rings required for
2x6 Wall with
Isolation and Crimpsert Connections Mounting Brackets
Balancing Valves (HRM5 or HRM7)
26
SYSTEM PRESSURE TESTING
The system must be pressure tested before the
loops are embedded in the slab or otherwise
covered. As a minimum, the internal system pressure
should be raised to 100 psig and held for at least 30
minutes. If it is a warm day and the sun has warmed
the PEX tubing loops, there will be a slow expansion
of the tubing that will show as a pressure decrease in
the system. Depending on the ambient temperature,
the pressure decrease could be significant and may
require re-pressurizing the system back to 100 psig
and maintaining for longer than 30 minutes. As long
as the temperature remains relatively constant, the
pressure will stabilize if the system is leak-free.
If, after 2 hours test time the pressure cannot be stabilized, then there is probably a leak. Find and repair
the leak and retest. It is paramount to system integrity that the loops are leak-free before covering. If a
loop tube has been damaged during installation it is recommended to replace the entire loop and not
install a repair coupling. Repair couplings are intended as a “last resort” repair during the pour when it is
impossible to replace a damaged loop.
When pouring the floor covering, pressurize the system with 30 to 50 psig of air so that any damage
occurring during the pour will immediately be evident and a repair can be made. Use only a Vanguard
Crimpsert repair coupling of the correct size with heat shrink sleeve covering for loop repair. The crimps
must be checked with a Go/No-Go gauge and the system must be re-pressurized and the repair
checked for leaks before shrinking the heat-shrink tubing over the coupling and crimp rings and burying
the repair in the slab.
CAUTION! Overnight testing is not recommended as it results in erroneous test

results. Large swings in ambient temperature will show dramatic changes in test
pressure as the loop tubes expand and contract with temperature. Even the air
inside the loops expands and contracts with temperature and will lead to erroneous
readings that could be indicative of a leak when no leak exists. Always start the test when the
ambient temperature will remain relatively constant for the test duration.
CAUTION! If water is used for system pressure testing it must be protected from
freezing if there is even a remote possibility that the ambient temperature will drop
to freezing or below before the structure is completed and the system is operating.
The antifreeze must be of sufficient concentration to protect the system at least to the
lowest expected temperature. Antifreeze and water must be mixed well before filling the system.
Failure to protect the system from freezing will result in ruptured tubing loops within the slab and at
expansion joints and can crack the slab severely. Repair is very costly and must be avoided.
27
SYSTEM FILLING AND AIR ELIMINATION
After all of the loops have been connected to the manifolds, that portion of the system can be filled and
purged of air. Alternately, the system can be pressurized with compressed air for leak detection and to main-
tain pressure on the system during the slab pour (see page 27) and the entire system (including transfer pip-
ing and the hot-water source) can be filled and purged at one time. Whether done in one or several stages,
purging is a critical step since air entrapped in the system will inhibit or prevent fluid flow through some or
possibly all of the loops, zone piping or transfer piping.
The system must have at least one air vent device (Vanguard part# HRSMAV) and, for large-scale systems,
there may be several air vents at key points in the system. The primary air-vent should be located between
the water heating device and the circulator pump. This should be the point of lowest pressure in the system.
Open the vent to the atmosphere while filling/purging the system to allow free escape of air. When fluid be-
gins to escape from the air vent, close it and continue filling/purging the system
It is recommended that the system be filled only with a water/antifreeze mixture of sufficient concentration to
protect the system from freezing down to at least the lowest expected temperature. Please realize that con-
struction schedules can change and a poured slab may sit for some indeterminate amount of time before the
building is erected and an unprotected system can freeze resulting in catastrophic damage to the PEX tubing
loops, manifolds and the slab.
Loop and zone valves are important for purging as it allows individual control of purge flow to develop the
needed fluid velocity to force out air.
Connect the supply and return
To affect the most efficient purging, each zone and loop should
lines from the filling/purging sys-
be purged individually. The key to purging is to create a high-
tem to the built-in fill/drain con-
velocity flow through the tubing to force air out of the system.
nections on the manifolds.
Circulation pumps are generally low flow and may not provide
the needed velocity. Purging is best accomplished with a purge COMAP SIMPLEX
cart. A purge cart is basically a container for mixing the water/
antifreeze solution and a pump capable of developing a mini-
mum velocity of 5 feet/second in the piping being purged. The
fluid is pumped into the system and is returned back to the
mixing container until the return fluid is essentially free of air
bubbles line. Enough fluid must be kept in the mixing container
Fill/Purge
at all times during purging to prevent re-introduction of air into Garden
the system. Absolute air removal at the purging stage may not Hose Fit-
always be practical but removing as much air as possible during tings
this step will help to ensure a properly operating system.
The Comap and Simplex manifolds have built in fill/purge

connections to fit a standard garden hose fitting. Other mani-
fold types will need to be filled/purged through a different type
of connection. For purposes of filling/purging, a flexible hose Fill/Purge Garden Hose Fittings
can be connected with a Crimpsert fitting using ordinary hose
clamps. Connect the pressure side of the purge pump to the Other manifold types require
supply manifold and another line that returns to the mixing separate fittings to connect the
container to the return manifold. Close all of the loop isolation filling/purging system.
28
SYSTEM FILLING AND AIR ELIMINATION
valves on both manifolds and start the purge pump. Working one loop at a time, open the isolation valves on
the supply and return manifolds and watch the return water flow back into the mixing container. Continue to
pump fluid until there is little, if any air bubbles in the return fluid stream. Close both isolation valves for that
loop and open the valves for the next one. Continue this process for each loop on each zone.
When all manifolds and loops have been purged, the system can then be pressurized for leak tightness test-
ing (see page 27) and then a lower pressure can be held on the system during the pour so that any inciden-
tal loop damage can be located immediately and repaired.
If when the pour is complete and some time will pass before the supply/return piping is connected, depres-
surize the system and close all loop isolation valves and all zone isolation valves. When the remainder of the
system is connected, filling and purging is done in exactly the same fashion as above but the zone isolation
valves will be used to purge individual parts of the system instead of loop isolation valves. When filling/
purging supply/return piping, leave all of the loop isolation valves closed to concentrate the fluid flow through
the supply/return piping and manifolds. After all of the zones have been filled and purged, the loop isolation
valves can then be opened.
If filling/purging will be done only after all of the piping is in place, follow the same procedure as outlined
above but work one loop on one zone at a time using the isolation valves. When system purging is complete,
the purge pump can be used to pressurize the system to 15-20 psig.
Small amounts of air remaining in the system will eventually vent, however; too much air can congregate into
a larger bubble and stop pumping action altogether. Also, some boilers can be damaged by excessive air in
the system.
A flow meter in the transfer tubing is a good

diagnostic tool and will show not only that fluid is
flowing but will also show air bubbles (for clear
meters) in the system. Remember that air in the
system should be eliminated to the greatest ex-
tent possible before startup to prevent operational
problems later.
Each system must have an expansion tank to pro-

vide for expansion and contraction of the fluid as
it is heated and cooled. Open expansion tanks are
not recommended since they will introduce air into
the system continually. Use a tank with a flexible
bladder that separates the air-charge from the fluid.
Charge the air side of the tank 2 to 3 psig below
the system charge pressure.
A simple fill/purge system consists of a container for mixing

the water and antifreeze, a motor-driven pump and hoses to
connect to the radiant system.
29
SYSTEM CONTROLS
Even the simplest system requires some form of control to sense the temperature of a room or rooms
and turn the circulation pump on and off as required to maintain the proper temperature. All of the
Vanguard control systems operate on low voltage 24 volt AC current.
The number and location of thermostats, zone or loop valves, temperature sensors, etc. must be known
so that the necessary wiring can be installed throughout the structure prior to the wall finishing being
applied. Typical control wiring is 18 AWG solid wire but the local electrical code may have different
requirements. Control wiring must not be run parallel with telephone or AC lines or other sources of
electromagnetic noise as this can affect the signal and may result in faulty operation. Twisted-pair or
shielded cable, or running the wiring through grounded metal electrical conduit are options to prevent
interference.
Due to size of some systems or necessity of control features, there can be a substantial number of
control wires routed back to the mechanical room or other control location. Each wire (or pair as the
case may be) must be marked as to the function that it serves. A mass of unmarked wires coming from
different parts of a structure is a nightmare to sort out. Always mark each wire run as it is being installed
to prevent unneeded problems.
One key to system comfort in large structures is providing sufficient controls to provide on/off operation
of not only the entire system but also of individual zones and even individual loops. South facing rooms
with ample glass may require a separate thermostat to turn off the zone (or zones) when radiant gain
from the sun is high. This on/off action can be provided by zone valves (or loop actuators) or individual
circulation pumps.
Since each system is different, there are potentially thousands of control schemes and it is impossible
to illustrate them all within the scope of this installation guide. Instead, we recommend that you contact
Vanguard or the control system supplier for a detailed guide for the control unit(s) being utilized. The
wiring schematics for the particular control being used must be consulted to ensure the proper wiring is
installed.
Outdoor Whole House
Sensor Control
Zone or Room
Thermostats
Boiler
Sensor Circulators
and/or
Motorized
Zone Valves
Simplified c
for automatic control of circulator(s) and/or Motorized Zone Valve(s). While not all systems will require this level of feedback and control, even
simple systems need some form of thermostatic control to turn the system on and off.
30
PIPING SCHEMATICS
While there are any number of ways to pipe a radiant floor heating supply/return system, and it would
be impossible to illustrate every potential configuration, the schematics on the following pages represent
several ideas that can be used "as is" or modified to suit individual system needs. Also, there are some
basic guidelines that should be followed to prevent operational problems with modified piping layouts.
1) Each system or isolated part of a system needs an expansion tank. As the fluid in the system is heat-
ed and cooled, and during the off-season, there is a volume differential in the system that is best
accommodated with a bladder expansion tank. The charge pressure in the air-side of each expansion
tank should be a few psig below the static system pressure.
2) Expansion tanks are best placed upstream of circulators.
3) An air vent or, preferably, an air separator, should be installed at a point in the system or each iso-
lated part of a system where the pressure is the lowest (upstream of circulator) and the fluid temp is
the highest (just downstream of the water heating unit). This provides the most efficient air removal.
4) Isolation valves at each circulator and manifold will facilitate filling and purging and simplify replace-
ment of a failed or worn-out component.
5) Zone circulators are preferred to motorized zone valves in multiple-zone systems. Installing a circu-
lator on each zone provides for partial system operation in the event of a single circulator failure.
6) Using a single circulator and motorized zone valves on a large multiple-zone system may require a
pressure activated bypass loop to prevent excessive head-pressure during single zone operation.
7) Never connect the system to the potable water system with an auto-fill valve. This is especially im-
portant for snow-melt systems. Unknowingly filling a leaky system with plain water can dilute the an-
tifreeze concentration to a dangerously low level and can result in a system freeze-up. If an auto-fill
is required, use a separate pressure tank with a water/antifreeze mixture of sufficient concentration.
Charge the tank above the static system pressure and connect it through a pressure-reducing valve
(PRV).
8) Non-condensing boilers may require the addition of a manually or automatically controlled bypass
loop to maintain return water temperature above the boiler manufacture’s recommendations to pre-
vent condensation of flue gases and acid production.
9) Size the circulator(s) for the portion of the system it (they) will be supplying. The primary circulator
in a primary/secondary-circulator system must be sized for the total demand it must supply through
the total length of piping in the primary piping circuit.
Schematics Legend
The illustrations below are used throughout the schematics section to define system components.
Manifolds and
Air Flow Motorized Radiant Panel
Elimination Check Zone Valve Loops
Device Valve
Isolation or 3-Way
Expansion Circulator
Balancing Thermostatic
Tank Pump
Valve Mixing Valve
31
PIPING SCHEMATICS
Single Zone Simple System

For small, single-zone systems using a condensing boiler, water heater, or when supplied from the
domestic hot-water supply, the system can be piped similar to the schematic below. The floor panel
supply water tempering is through a manually-set, 3-way thermostatic mixing valve. System on-off
control can be accomplished through a single thermostat or may also incorporate outdoor and floor
temperature sensors to offer more even room temperature.
When the radiant panel is supplied from the domestic hot-water system (when allowed by code), the
expansion tank and air elimination device may be omitted. Some systems will require a balancing valve
in the loop return to provide for return-side flow resistance to assure adequate return supply to the
thermostatic mixing valve..
When supplying the radiant system

from the domestic hot water system,
expansion tank and air elimination
device may be omitted.
Hot
Mixed
Cold
Balancing valve is
Condensing Boiler optional but may be
Water Heater or required to provide
Supply from the return-side flow
Domestic Hot resistance
Water System
32
PIPING SCHEMATICS
Single Zone Using Simply Radiant (HRZCP1) Control Box

The HRZCP1 Control Box simplifies installations for single-zone systems up to 30,000 BTU. The zone
pump, mixing valve and temperature control are all housed within the Control Box. The provided wall
thermostat connects to the control box and provides on/off control by sensing room air and floor
temperatures. The control also provides for high/low floor temperature limits.
When the system is supplied from the domestic hot-water system (when allowed by code), the
expansion tank and air elimination device may be omitted. Some systems will require a balancing valve
in the loop return to provide for return side flow resistance to assure adequate return supply to the
thermostatic mixing valve.
When supplying the radiant system Supplied Wall Thermostat Senses

from the domestic hot water system, Room Air Temperature and Floor
expansion tank and air elimination Temperature
device may be omitted.
HRZCP1
Zone Con-
trol
Condensing Boiler
Water Heater or
Supply from the
Domestic Hot
Water System
Balancing valve is optional but

may be required to provide
return-side flow resistance
33
PIPING SCHEMATICS
Multiple Zones Using Simply Radiant (HRZCP1) Control Boxes

For larger systems with multiple zones, several HRZCP1 Simply Radiant Control Boxes can be supplied
from a primary circulation loop off the hot water source. Each zone served by a Control Box then has its
own floor and air temperature sensors to provide space temperature control. Please note, the diagram
shown is not suitable for a noncondensing boiler. (See the diagram on page 40 for non-condensing
boiler primary loop piping.)
When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop
must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the
secondary loops when the primary circulation pump is in operation. Additional secondary loops can be
supplied from the primary loop. Please note that the hot water source must be capable of supplying
the needed heat output and that the primary piping loop must be sized according to the total system
demand of all secondary loops.
Some points to remember when installing this type of system

- Check valves must be installed on the supply side of each secondary loop and optionally on each
return side
- Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia.
of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies
to each secondary loop.
HRZCP1
Zone Control
Secondary
Loop
6” 4 x pipe dia.
max.
8 x pipe min. Supplied Wall
dia. min. Thermostat
Senses Room
Hot Water Air Temperature
Source and Floor Tem-
(if boiler, Primary Loop perature
must be
condensing
type)
Secondary
Loop
HRZCP1
Zone Control
34
PIPING SCHEMATICS
Multiple Zone Single-Temperature System Using Motorized

Zone Valves Installation
Multiple heating zones requiring a single zone supply temperature using motorized zone valves in place
of zone circulators can be piped similar to the schematic below. By using a 3-way thermostatic mixing
valve on the primary boiler loop and then adding secondary zone loops as needed, the system can
provide a single supply temperature to all connected secondary loops. Zone valve systems should be
piped with supply and return manifolds on the primary loop to insure proper circulation in the secondary
loops. Please note that by relying on a single circulator pump only on the primary loop, that partial
system operation in the event of a pump failure is not possible.
For even pressure balancing between secondary loops, the connection of the secondary supply and
return lines to the primary manifolds should be piped in a first-out/last-in fashion where the first
secondary loop on the supply manifold (closest to the supply pipe) is the last loop on the return
manifold (furthest from the return pipe).
Additional zones can be added provided the heat source and the main circulator are properly sized for
the entire demand. However, as the primary circulator size is increased, the need may arise to install
a bypass loop in the primary circuit to prevent excessive pressure when only some of the secondary
circuits are in operation.
The system shown below can also be piped to supply different temperatures to each secondary loop.
By removing the thermostatic mixing valve from the primary loop and installing one on each secondary
loop as required.
NOTE! Large systems with numberous Service Valves

zones may require pressure controlled (Optional)
primary bypass loop to prevent exces-
sive pressure.
Hot Mixed
Condensing Cold Supply

Boiler Water
Heater or Sup- Return
ply from the Balancing valve is optional
Domestic Hot but may be required to
Water System provide return-side flow
resistance
35
PIPING SCHEMATICS
Multiple Zone Single-Temperature System Installation

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

return side
Secondary
Loop
Hot
Mixed
Cold
6”
max.
8 x pipe 4x
dia. min. pipe
dia.
min.
Condensing
Boiler Water
Heater or
Supply from
the Domestic Secondary
Hot Water Primary Loop Loop
System
Balancing valve is optional but may be required

to provide return-side flow resistance
36
PIPING SCHEMATICS
Multiple Zone Multi-Temperature System Installation

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

return side
Hot Mixed
Multiple supply water temperatures
are achieved with 3-way thermo- Cold
static mixing valves as needed for
different supply temperatures.
Secondary
Loop
6”
max.
4x
8 x pipe pipe
dia. min. dia.
min.
Primary Loop
Condensing Boiler
Water Heater or
Supply from the
Domestic Hot
Water System
Secondary
Loop
37
PIPING SCHEMATICS
4-Way Mixing Valve Installation

A motorized 4-way mixing valve provides automatic control of both loop supply water temperature and
return boiler water temperature and is best suited to a non-condensing boiler but can also be used on
condensing boilers. By sensing the temperatures of the loop supply and boiler return, the control ad-
justs the position of the 4-way valve through the 4-way valve motor. Loop supply and boiler return are
constantly adjusted to maintain the correct temperatures. The 4-way valve must be connected to the
primary circulation loop through closely spaced tees not more than 6” apart.
The control may also be equipped with an outdoor sensor to provide anticipation control based on out-
door temperatures.
Outdoor Sensor
(if equipped)
Supply Sensor
Heated Loop
Supply
Control
Valve Motor
Cooled Loop
Return
Condensing
Boiler 4-Way Valve
Boiler Return Sensor
38
PIPING SCHEMATICS
Variable Speed Injection Pump Installation

A Variable Speed Injection Pump is another method of providing tempered water from higher tempera-
ture boiler water. Injection mixing can be used to temper an entire single temperature primary loop by
connecting it to a circulating boiler loop, or can be used to temper a secondary loop when connected to
a primary loop.
The injection pump is controlled by a temperature sensor on the tempered loop and the speed of the
pump is varied to inject enough higher temperature water into the cooled return water to achieve the
desired mix.
A flow restriction valve is generally required on the injection return line to increase headloss in the circuit
to match the pump’s output curve.
Loop or
Temperature Sensor
Zone Sup-
ply
Variable Speed
Injection Pump
Heated
Supply
Primary or
Primary or
Secondary
Boiler Loop
Loop
Loop or
Flow
Boiler Zone
Restriction
Return Return
Valve
39
PIPING SCHEMATICS
Non-Condensing Boiler Installation

Conventional, non-condensing boilers need protection of the return water temperature to prevent flue-
gas condensation that can result in corrosion and lead to premature boiler failure. For non-condensing
boilers, a 3-way thermostatic mixing valve can be piped as shown above. The mixing valve can be set
to provide a tempered return water to the boiler to prevent flue-gas condensation from too cold return
water. Consult the boiler manufacturers recommendations to set the mixing valve.
The remainder of the simple or primary/secondary system is piped the same as shown on the pro-
ceeding schematics.
Heated primary
loop supply
Hot Cold
Cooled primary
loop supply
Mixed
Non-condensing Boiler
40
PIPING SCHEMATICS
Thermal Trap Installation

While not required, flow-check valves on the return side of secondary loops will further prevent un-
wanted circulation of the secondary loop during off-times even though the primary loop is operating. As
an alternative to a flow check on the return side only, a thermal trap as shown below can be installed.
The leg must dip at least 18 inches below the primary loop line to be effective.
Whether a thermal loop is used or not, the same close spacing of secondary loop supply/return tees
must be followed (maximum 6 inches). Also, a drain fitting may be fitted to the bottom of the thermal
trap to facilitate draining.
Heated primary
loop supply
18” Thermal traps can replace flow-check

Min. valves on secondary loop return lines.
41
APPENDIX A
DAILY TOOL CALIBRATION CHECK

Accurately adjusted crimping tools are critical to the success of this fitting system. If the crimped rings
do not gauge properly, the tools need adjustment. The method for checking the crimping tool for proper
calibration is:
1. Assemble and crimp a fitting.
2. Slide the correct size “GO” side of the crimp gauge over the crimp ring in at least
FOUR places. DO NOT gauge the crimp at the jaw overlap area.
3. If the “GO” side of the gauge fails to slide over the ring at any point, the crimp tool
requires calibration (ring is under crimped).
REMEMBER: A crimp tool which has worn parts may not calibrate. Return worn
tools for repair or replacement.
4. If the “GO” side slides over the crimp ring, attempt to slide the correct size “NO
GO” side of the gauge over the crimp ring in at least four places.
DO NOT gauge the crimp at the jaw overlap area.
5. If the “NO GO” side of the gauge slides over the crimp ring at any point, the crimp tool requires calibra-
tion (ring is over-crimped).
REMEMBER: A crimp tool which requires frequent calibration may require repair or replacement.
42
APPENDIX B
ADJUSTING “HCM” TOOLS

The HCM compact crimp tools are generally not capable of over-crimping (the
NO/GO gauge fits over the crimped ring). However, normal wear may cause
the crimp size to increase to above the maximum allowed (the GO gauge does
NOT fit). Tools manufactured prior to December 1996 must be returned
for calibration if they do not crimp to the dimensions shown on page
42. Tools manufactured after that date have an adjustment feature
built in and are easily identified by a hex head on the back-pin, see the
figure to the right. These tools may be adjusted to decrease the crimp
diameter up to five times.
When an HCM crimp tool requires adjustment to a smaller

crimp dimension, note the number to which the line on the hex
head of the back pin points. (See Figure 1)
Carefully remove the retaining clip by inserting a small flat blade screwdriver in
CAUTION!
the loop of the clip and turning the screwdriver.
The retaining clip is
made from spring
From the clip end of the back pin, push it towards the tool body until the hex
steel and may fly off of the
head on the other end of the pin just clears the body.
pin if not removed carefully,
possibly causing eye damage
Rotate the pin until the line on the hex head points to the next higher number
and loss of the clip.
on the frame. Push the pin back into the frame and replace the retaining clip.
To reduce crimp size, rotate Back Pin to Next Higher Number
Crimp a test joint and check the crimped ring for proper sizing with a GO/NO GO gauge or by measurement.
Severely worn tools may require further adjustment. As the tool continues to wear with use, simply repeat these
instructions as required.
43
APPENDIX C
ADJUSTING “HAR” TOOLS

An accurately adjusted crimping tool is critical to the success of this fitting
system. If the crimped rings do not 1.
gauge properly, the tool
needs adjustment. Open
the tool
han-
HAR TOOL dles.
The method for adjusting the HAR tool is:
2. 3. 4.
Note the Carefully remove Test the tool by crimping a joint
position of the retaining and checking the crimped ring
the notched screw and with the “GO” gauge. If the “GO”
head of the rotate the cam gauge slides over the ring then no
adjustment counter- further adjustment is needed. If
cam in clockwise the “GO” gauge will not slide over
relation to slightly until the crimped ring, then repeat the
the the retaining Reinstall Retaining adjustment by rotating the adjust-
Retaining Screw
Phillips- Screw
screw can be ment screw counterclockwise an
head installed in the other additional 1/2 notch and reinstall-
Adjustment Cam
retaining threaded hole. This provides about ing the retaining screw in the other
screw. 1/2 notch of adjustment. threaded hole.
A tool adjusted to the middle of the crimp diameter range may reduce the frequency of calibrations.
44
APPENDIX D
Vanguard Vanex series PEX Repair Kit

The Vanguard XLHRK3 (1/2”) and XLHRK4 (3/4”) field repair kits are for Vanex series PEX tubing
in radiant heating installations. While the best policy is to use only continuous lengths of tubing
for in-slab hydronic heating loops, extenuating circumstances may dictate that a loop be repaired
due to a kink, puncture or other damage. If the loop is damaged in more than one location, we
strongly recommend that the entire loop be replaced. Undamaged lengths of the replaced loop
can be further utilized by cutting out the damaged section and using the remaining length(s) for
other, shorter loop(s). Please read and understand these instructions before attempting a repair.
Failure to follow these guidelines may result in leakage or failure of the repair. It is the responsi-
bility of the user to read and understand these instructions in their entirety prior to attempting a
repair.
1) Make a clean cut on both sides of the damaged area. Cut the tubing cleanly and square.
2) Slide the provided, 1” heat shrink tubing onto one end of the cut PEX and back a few
inches.
Slide the provided crimp rings onto each end of the cut PEX and insert the fitting into both
tubes until the ends contact the tube stop on the fitting. Position each crimp ring 1/8” to
1/4” from the end of the tubing. See Figure 1
Figure 1
3) Using the correct size PEX crimping tool, crimp each ring while holding the tool at a 90¡
angle to the tube with the jaws of the tool centered over the ring. After completing both
crimps, check each one using the GO/NO-GO gauge (HAC34),. The GO portion of the
gauge must slide over the crimped ring (except at the jaw overlap area) and the NO-
GO portion of the gauge must not slide over the ring. If either or both of the completed
crimps fail to pass a GO/NO-GO gauging, the connection must be cut out completely and
replaced. Use a new fitting and crimp rings and trim back the PEX tubing on both sides to
eliminate the previously crimped portions. Make any necessary adjustments to the crimp
tool and remake the connection. Recheck the crimps with the GO/NO-GO gauge. Do not
proceed until both of the crimps pass the gauging test. For further information on the
crimping procedure, gauging of completed crimps or crimp tool adjustment procedures,
refer to the Installation Guidelines for Vanex PEX (available from Vanguard).
4) Pressurize the repaired loop and check for leaks. We recommend a pressure of 100 psig
and a minimum time of 15 minutes. If the joint passes both a gauging and a pressure test
proceed to the next step. If the connection fails either test, cut out the connection, make
any necessary tool adjustment and remake the connection.
45
APPENDIX D
Vanguard Vanex series PEX Repair Kit (cont.)

6) Slide the length of heat-shrink tubing over the repair joint so that it is approximately cen-
tered. See Figure 2
Figure 2
7) Using a heat-gun on the low setting, apply heat to the shrink tube evenly with a constant
motion. Never use an open flame! Continue heating until the shrink tube conforms to the
shape of the joint and pulls down snugly around the tubing. See Figure 3.
Figure 3
8) The repair should be allowed to cool for a few minutes before final placement of tubing.
46
Notes:
47
CONTINENTAL UNITED STATES
1-800-775-5039
OUTSIDE UNITED STATES
1-620-241-6369
FAX
1-800-775-4068
www.vanguardpipe.com
901 N. Vanguard Street

McPherson, KS 67460
QHMN02VS 1.04
48

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INSTALLATION INSTRUCTIONS

Thank you for choosing the Vanguard System.

A minimum hydronic radiant ﬂoor heating system includes:

3. Manifold or manifolds to distribute

4. Vanex PEX tubing loops installed in HEAT SOURCE

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

VANEX PEX TUBING

TEMPERATURE & ASTM INCREMENTAL

VANEX HYDRONIC HEATING MANIFOLDS

Comap Manifolds Simplex Manifolds

VANEX PEX TUBING FOR SUPPLY AND RETURN PIPING

VANEX CRIMPSERT® FITTING SYSTEM

BOILERS, PUMPS AND OTHER SYSTEM COMPONENTS

Injection Mixing - A method of providing temperature-controlled supply water by injecting high-

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

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

◆ Pressure test the system before pouring the concrete or other

◆ DO NOT use tubing that is damaged. DO NOT connect shorter

◆ Inform the other trades working on the same structure of the

◆ Follow the guidelines for attaching the PEX tubing.

ADDITIONAL CONSIDERATIONS BEFORE STARTING

Typical loop spacing is 4" to 15" and is dependent on the location of

120° 120° 140° 140°

Alternately, the loops can be connected to the manifold immediately but

If the manifolds have not been placed prior to installation of the

WARNING! Excessive sunlight exposure will damage

For rooms with no exterior wall, it is recommended to use

Tie the tubing to the re-bar or re-mesh every 3-4 feet

Elbows or sleeving may

CAUTION! DO NOT drill into or drive fasteners into the slab

When attaching insulation to the slab forms prior to pouring, adjust

Perimeter insulation is also TO FROST

Edge and perimeter insulation will

The top of exposed edge

If fastening the PEX tubing directly to the foam insulation, see

In some rare instances, the PEX tubing must be placed in the

SLEEVE PEX TUBING AT ALL EXPANSION JOINTS WITH HRCSL3 OR HRCSL4

SLEEVE EVERY POINT

OVER AN EXISTING SLAB

WHEN USING STAP1 OR

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR

Insulation Install only continuous loops of tubing into the

There must be at least 3/4" of poured underlayment/thin 3/4"

The joist spaces below the heated ﬂoor must be 3”

NOTE! Insulating below a radiant ﬂoor

NOTE! Install plastic elbows (HRSL3 or

POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR

Other than the attachment of sleepers to the sub-ﬂoor,

Leave sufﬁcient space between sleeper ends to make turns and

Insulation of a thin-slab with

INSTALLATION BELOW THE SUB-FLOOR Subﬂoor

The illustration above shows the most common method of pulling

Holes through joists for tubing bundles must be sufﬁciently sized

CAUTION! The fasteners must

FOIL FACE OR RADIANT BARRIER

R11 MINIMUM OVER HEATED

For systems requiring more than one delivered water temperature,

It is not required to install manifolds in a dedicated space such as the

SOME SYSTEMS REQUIRE THAT RADIANT MANIFOLDS BE INSTALLED IN SEPARATE LOCATIONS.

Loop connections are available in Euro-compression

The end connection kit features a 1" female NPT

Loop connections are available in Euro-