How to Add a New Hydronic Heat Zone
- 1). Draw a layout of the project, including the length of the "send" and "return" pipes leading from the boiler/manifold to the new space. In addition, include the dimensions for the space for the new heating. The "send" pipe refers to the pipe that supplies the hot water for heating the space.
- 2). Include in the sketch the connection points for the mixing valve and circulator pump. The mixing valve combines hot water from the boiler with cold water from the return, which helps control the temperature in the zone. Indicate on the drawing the "return" pipe and the pipe connecting the mixing valve and the "return" pipe. Discuss the project with the supply vendor, who has the technical knowledge to answer questions and provide tips.
- 3). Shut down the heating system. Install the new ¾-inch zone valve on the existing manifold. The manifold functions like a control center for running separate supply lines to the different zones. The zone valve enables you to control the flow from the manifold as well as the temperature of the space. Connect ¾-inch copper pipe from the zone valve; run the pipe to the point of installation of the mixing valve. Install the mixing valve.
- 4). Connect the ¾-inch copper pipe to outlet of the mixing valve. Run ¾-inch copper pipe from the outlet in the center of the mixing valve to the connection point, where the pipe ties into the return line. Use a pipe cutter to cut the copper pipe of the return line. Insert a copper "T" and install the end of the pipe leading from the mixing valve into the "T."
- 5). Follow instructions for connecting the circulator pump to the water line. Connect ¾-inch copper pipe to the outlet of the circulator pump; continue running the ¾-inch copper pipe to the location of the tubing.
- 6). Insert the tubing into the channels of the aluminum joist panels. Staple panels underneath the subfloor between the floor joists. Staple the panels every 4 to 6 inches on each side of the channels. Place the staples about ½-inch from the channels. Consult the building code for instructions on the proper method for drilling holes in the floor joists. Pull the tubing through the holes; continue installing the panels and tubing.
- 7). Use the pipe cutter to cut the pipe where the return line connects to the boiler. Install a "T." Run ¾-inch copper pipe from the connection to the end of the tubing. Connect the supply and return lines of the tubing to the ends of the copper pipe. Follow the instructions for pressure testing the system for leaks. Install the sensor and thermostat, which control the temperature of the new zone.
Source...