Viega Climate Trak User manual

Installation Manual
Viega Climate Trak® Heating System

3 of 40IM-HC 530590 0621 Climate Trak (EN)
Table of Contents
Table of Contents
1 About this Document ______________________________________ 5
1.1 Disclaimer ____________________________________________ 5
1.2 Symbols Used _________________________________________ 5
2 System Overview _________________________________________ 6
2.1 Application Bene󶈵ts ____________________________________ 6
2.1.1 Climate Trak ____________________________________ 6
2.1.2 Heat Transfer Plates _____________________________ 6
3 System Design ____________________________________________ 7
3.1 Calculating a Materials List ______________________________ 7
3.2 Heat Loss Calculations for Floor Heating Systems ___________ 8
3.3 Calculating the Supply Water Temperature _________________ 9
3.4 Calculating the Floor Surface Temperature ________________ 10
3.5 Calculating the Pressure Drop ___________________________ 11
3.6 Selecting a Circulator Pump ____________________________ 12
4 Climate Trak / Heat Transfer Plate System Installation _______ 13
4.1 Pre-Installation Tips ____________________________________ 13
4.1.1 Avoiding Obstructions ___________________________ 13
4.2 Clearing the Bays _____________________________________ 14
4.3 Drilling Tubing Holes ___________________________________ 14
4.4 Attaching the Traks/Plates ______________________________ 15
4.5 Installing the Tubing ___________________________________ 16
4.6 Post-Installation Tips - Insulation _________________________ 17
5 Piping and Controls _______________________________________ 18
5.1 Mixing Station and Manifolds ____________________________ 18
5.2 Radiant Systems ______________________________________ 19
5.2.1 Single Temperature Radiant System with Boiler
Modulation and Optional DHW Control ____________ 20
5.2.2 Multiple Temperature Radiant System with Boiler
Modulation and Optional DHW Control ____________ 21
5.3 Zone Wiring __________________________________________ 22
5.3.2.1 Wiring Schematic: One Zone Application ____ 22
5.3.2.2 Wiring Schematic: Multi-Zone Application ___ 23
6 System Start-Up __________________________________________ 24
6.1 Station and Actuator Installation _________________________ 24
6.2 Purging and Pressure Testing the System _________________ 25
6.2.1 Purging _______________________________________ 25
6.2.2 Pressure Testing _______________________________ 26
6.3 Adjusting the High Limit Kit _____________________________ 27
6.4 Initial Balancing _______________________________________ 28

4 of 40 IM-HC 530590 0621 Climate Trak (EN)
Table of Contents
7 Finish Flooring ___________________________________________ 29
7.1 Choosing a Finished Floor ______________________________ 29
7.1.1 Floor Surface Temperatures ______________________ 29
7.1.2 Moisture ______________________________________ 30
7.1.2.1 Dry Shrinkage ___________________________ 30
7.1.2.2 Wet Expansion __________________________ 30
8 Appendix A: Making a Press Connection ___________________ 31
9 Appendix B: SVC Compression Coupling ⅜" to ⅝" __________ 31
10 Appendix C: Recommended Tools for Installation ___________ 32
10.1 Installation (Power Tools) _______________________________ 32
10.2 Installation (Hand Tools) ________________________________ 32
10.3 Miscellaneous ________________________________________ 32
11 Appendix D: R-Value Floor Coverings ______________________ 33
12 Appendix E: Supply Water Temperature/BTU Output Charts _ 34
13 Appendix F: Making a Material List_________________________ 37
13.1 Climate Trak Material Worksheets ________________________ 37
14 Limited Warranty _________________________________________ 38
14.1 Limited Warranty for Viega Heating and Cooling Solutions ___ 38
List of Tables
Table 1 Multipliers for Climate Traks _____________________________ 7
Table 2 Multipliers for Heat Transfer Plates ________________________ 7
Table 3 Maximum Circuit Length ________________________________ 7
Table 4 Viega Barrier PEX Tubing Data __________________________ 11
Table 5 Radiant System Materials ______________________________ 19
Table 6 Primary Loop Sizing ___________________________________ 19
Table 7 Single Temperature Radiant System Materials _____________ 20
Table 8 Multiple Temperature Radiant System Materials ____________ 21
Table 9 Primary Loop Sizing ___________________________________ 21
Table 10 Station and Actuator Materials __________________________ 24
Table 11 R-Value Floor Coverings _______________________________ 33
Table 12 Climat Trak Material Worksheets ________________________ 37

About this Document
5 of 40
IM-HC 530590 0621 Climate Trak (EN)
1 About this Document
DANGER!
This symbol warns of possible life-threatening injury.
WARNING!
This symbol warns of possible serious injury.
CAUTION!
This symbol warns of possible injury.
NOTICE!
This symbol warns of possible damage to property.
Notes give additional helpful tips.
1.1 Disclaimer
1.2 Symbols Used
The following symbols may be used within this document:
Viega products are designed to be installed by licensed and
trained plumbing and mechanical professionals who are
familiar with Viega products and their installation. Installation
by non-professionals may void Viega LLC’s warranty.
This document is subject to updates. For the most current
Viega technical literature please visit www.viega.us.

System Overview
6 of 40 IM-HC 530590 0621 Climate Trak (EN)
1. Heavier aluminum than the Heat Transfer Plates
2. Fastest installation time (does not require Groove Tube)
3. Easiest to install (Traks and tubing are installed separately, so there is
no struggling with the tubing while the fastening is being done)
4. Predrilled holes for ease of fastening with screws
5. Comes in 4' or 8' long Traks that also help with installation time
6. Snap-in groove for tubing maximizes contact between the aluminum
and the PEX Tubing for e󶈷cient heat transfer
In the following pages, you will be guided through the system design,
layout, installation, and start-up of the Climate Trak System.
Climate Traks and Heat Transfer Plates are designed for retro󶈵t
applications or in applications where the buildup above the sub󶈶oor is
a concern. These types of applications are not the most e󶈷cient kind of
radiant heating compared to systems such as Viega Climate Panel and
Viega Snap Panel, but deliver the comfort of having warm 󶈶oors and full
radiant heating throughout the house. Both methods utilize Viega Barrier
PEX tubing and attach directly to the underside of the sub󶈶oor. This is a
fast, lightweight application to install and provides the comfort of radiant
heat the homeowner is looking for.
2 System Overview
2.1 Application Bene󶈵ts
2.1.1 Climate Trak
1. Made from thinner, more 󶈶exible aluminum than the Climate Traks
2. Comes in 20" long by 5" wide plates
3. Requires a small bead of Groove Tube down the channel where the
tubing is run right before installation
2.1.2 Heat Transfer Plates
Systems should be protected from freezing at all times.
Proper insulation or glycol mixture may be needed in system
if not used for an extended period of the heating season.

System Design
7 of 40
IM-HC 530590 0621 Climate Trak (EN)
Multipliers for Climate Traks
Tubing OC Plate Size Tubing Multiplier Trak Multiplier
6" 4 ft
8 ft 2.2 .47 .23
8" 4 ft
8 ft 1.7 .35 .18
9" 4 ft
8 ft 1.5 .31 .16
12" 4 ft
8 ft 1.1 .23 .12
16" 4 ft
8 ft .85 .18 .09
18" 4 ft
8 ft .75 .16 .08
Table 1: Multipliers for Climate Traks
3 System Design
3.1 Calculating a Materials List
Multipliers for Heat Transfer Plates
Tubing OC Tubing Multiplier Plate Multiplier
6" 2.2 .93
8" 1.7 .70
9" 1.5 .62
12" 1.1 .47
16" .85 .35
18" .75 .31
Table 2: Multipliers for Heat Transfer Plates
Maximum Circuit Length
≤25 BTU/ft226-35 BTU/ft2
⅜"300 ft 250 ft
½" 400 ft 350 ft
Table 3: Maximum Circuit Length

System Design
8 of 40 IM-HC 530590 0621 Climate Trak (EN)
1. Calculate the total heated area.
2. Using the charts on the previous page and the total area, calculate
the total number of Traks/Plates and amount of tubing needed for the
job.
3. Using the circuit length chart, calculate the total number of circuits
needed.
Example: Heated Area - 1,500 sq. ft.
Calculating Number of Traks:
8 ft. Climate Traks 8" O.C.
# of Traks = 1,500 sq. ft. x .18
# of Traks = 270
- Sold in packages of 20:
(round up to order 14 boxes)
Calculating Amount of Tubing:
Amount of Tubing = 1,500 sq. ft. x 1.7
Amount of Tubing = 2,550 ft.
Calculating Number of Circuits (≤25 BTU/ft2):
Amount of Tubing = 2,550 ft.
2550 ft./400 ft. = 6.375
# of 1/2” circuits = 7
3.2 Heat Loss Calculations for Floor Heating Systems
Please reference ACCA Manual J, the ASHRAE Handbook, or CSA F280-
12 to determine heat loads. Viega o󶈴ers software that will perform a full,
multi-temperature, room by room, detailed design while calculating a
materials list and price quote for your system. Available in the program
is a full list of all Viega Heating and Cooling Solutions and PureFlow
products, instructions, speci󶈵cation sheets, manuals, and catalogs.

System Design
9 of 40
IM-HC 530590 0621 Climate Trak (EN)
3.3 Calculating the Supply Water Temperature
1. Locate desired BTU output (from Radiant Wizard) on left vertical axis.
2. Follow to the right until you reach the selected total R-value curve.
3. Then move down to the horizontal axis and read the supply water
temperature.
(For additional Climate Trak/Heat Transfer Plate BTU output charts, refer
to Appendix E).
5PUBM37BMVFPG'JOJTIFE'MPPS"CPWF4VC犕PPS
0.25
0.5
1.0
2.0
3.0
Supply Water Te mperature (°F)
Based on 68°F room temperature with R19 insulation between joists

System Design
10 of 40 IM-HC 530590 0621 Climate Trak (EN)
3.4 Calculating the Floor Surface Temperature
1. Locate desired output (from Radiant Wizard or other source) on left
vertical axis.
2. Follow to the right until you reach the curve.
3. Then move down to the horizontal axis and read the ∆T between the
room temperature and the 󶈶oor surface temperature.
4. Add the room temperature and the ∆T to get the 󶈶oor surface
temperature.
Example:
Output needed: 25 BTU/h/ft2
Room temperature: 68°F
Temperature ∆T (from chart): ~ 12°F
Floor surface temperature: 68°F + 12°F = 80°F
The 󶈶oor surface temperature will be 80°F with 25 BTU/h/ft2 output and
68°F room temperature.
This chart shows the relation between room temperature and 󶈶oor surface
temperature for 󶈶oor heating systems.
Floor Surface Temperature Chart

System Design
11 of 40
IM-HC 530590 0621 Climate Trak (EN)
3.5 Calculating the Pressure Drop
In order to select the correct pump size for the system, the pressure drop
must be calculated. Use the chart below to calculate the pressure drop.
1. Locate desired 󶈶owrate for one circuit on the left vertical axis (receive
circuit 󶈶owrate from the Radiant Wizard program).
2. Follow to the right until you reach the selected tubing size.
3. Then move down to the horizontal axis and read the pressure drop in
feet of head per foot of tubing.
4. Multiply pressure drop per foot by length of longest circuit.
Example:
GPM through ½” Viega Barrier PEX tubing: 0.7 GPM
Pressure drop per foot: ~ 0.022 ft. of head / ft.
Total pressure drop: 0.022 x 350 total ft. = 7.7 ft. of head
1 F T/S
2
3
4
6
7
10
20
30
50
5/16”
3/8”
1/2”
5/8”
3/4”
1”
1-1/4”
1-1/2”
Viega Barrier PEX Tubing Data
Nominal Size
(in)
Outside
Diameter (in)
Inside Diameter
(in)
Water Content
(in)
5
/
16*0.430 0.292 0.004
⅜ 0.500 0.350 0.005
½ 0.625 0.475 0.009
⅝ 0.750 0.574 0.014
¾ 0.875 0.671 0.018
1 1.125 0.862 0.030
1¼ 1.375 1.053 0.045
1½ 1.625 1.243 0.063
* 5 /
16” used in Climate Panel installation.
Table 4: Viega Barrier PEX Tubing Data

System Design
12 of 40 IM-HC 530590 0621 Climate Trak (EN)
3.6 Selecting a Circulator Pump
The pump must have a capacity equal to the system 󶈶ow rate and a head
equal to the system pressure loss. These two system characteristics are
the primary ones in selecting a pump. Flow rates come from the Radiant
Wizard program.
Pressure drop comes from the previous page or from the Radiant
Wizard program. Remember that for pressure drop, use the highest
pressure drop of all the circuits fed by their circulator. If the circulator can
overcome that pressure drop, then it can overcome all the others.
Procedure:
1. Locate the pressure drop on the left vertical axis.
2. Locate the total system 󶈶ow rate on the bottom horizontal axis.
3. Follow to the intersection of both variables.
4. Select the pump with a curve higher than this point.
Example:
Total GPM through ½" Viega Barrier PEX: 5 GPM
Longest circuit pressure drop: 10 ft. of head
Pump selected: Low Head Pump
Stock Code Speed Amps Watts HP
12126
HI 0.75 87 1
/
25
MED 0.66 80 1
/
25
LOW 0.55 60 1
/
25

Climate Trak / Heat Transfer Plate System Installation
13 of 40
IM-HC 530590 0621 Climate Trak (EN)
Place the Traks for the most even heat distribution.
Dimensions in drawing are based on standard 2" by 8", 2" by 10", or 2"
by 12" 󶈶oor joists on 16" centers. Adjust spacing as needed when using
engineered joists or di󶈴erent spacing.
4 Climate Trak / Heat Transfer Plate System Installation
4.1 Pre-Installation Tips
4.1.1 Avoiding Obstructions
It is important not to install the Traks around objects that will restrict the
tubing from being installed into the Traks. In the example below, if the
Traks were run on the inside of the dropping pipe, you would 󶈵nd that the
tubing would be unable to be snapped in. This is why the Traks are shown
going to the outside of the dropping pipe.

Climate Trak / Heat Transfer Plate System Installation
14 of 40 IM-HC 530590 0621 Climate Trak (EN)
4.2 Clearing the Bays
If support crosses can be easily removed, take them out to clear bays
for easier installation of the plates and Traks. If crosses are unable to be
removed, DO NOT drop tubing below them and resume on the other side;
install both plates and tubing above crosses so that no area is lost. Nails
must also be removed from bays. Whether you cut them, grind them,
or carefully bend them over, be careful not to damage the 󶈵nished 󶈶oor
above. (When cutting nails, be sure to wear safety glasses.)
4.3 Drilling Tubing Holes
Determine where the manifold will be located, then from there, decide
which end of the bays the tubing will be returning down. Use a right
angle drill with a 1¼" bit to drill a series of holes through each 󶈶oor joist.
Be sure to keep holes at least 3" from the sub󶈶oor to avoid 󶈶oor nails,
although having the holes centered would be the best for structural
strength.
Map out the circuits and determine which bays go to which circuits. Be
careful not to exceed maximum circuit length for the size of tubing you
are using (⅜" - 300 ft., ½" - 400 ft.).
Be sure to check with local building codes to ensure no
structural damage will occur with drilling the joists.

Climate Trak / Heat Transfer Plate System Installation
15 of 40
IM-HC 530590 0621 Climate Trak (EN)
4.4 Attaching the Traks/Plates
Start attaching the Traks via staples or zip screws (staples: 7 /
16" to ½"
crown by ¾" to 1", depending upon sub󶈶oor thickness; putting in 18
to 20 staples for an 8 ft. piece and 10 to 12 staples for a 4 ft. piece; zip
screws ¾" to 1", depending on sub󶈶oor thickness). Begin attaching Traks
8" to 10" from the closest hole that was drilled to allow ample room for
tubing to turn. Continue to install Traks the entire length of the bay (or to
where desired circuit ends) keeping the space in between Traks to around
1". Stop Trak installation 12" to 16" short of where you want circuit to
end (i.e., wall, main beam, room above) to allow for a non-stressful loop.
When stapling up Traks, be sure to keep staple gun square to avoid staple
de󶈶ection.
Safety glasses and ear protection are recommended.
Traks should be attached as 󶈶ush as possible to the
sub󶈶oor for best heat transfer.
When Traks are cut, be sure to debur them to avoid any
tubing damage.

Climate Trak / Heat Transfer Plate System Installation
16 of 40 IM-HC 530590 0621 Climate Trak (EN)
4.5 Installing the Tubing
Begin to make non-stressful (teardrop) type loops for each of the bays,
keeping loops small and manageable.
Continue making the “teardrop” loops, being sure not to install any of
the tubing into the Traks yet. Keep loops fairly small and manageable to
prevent twisting while keeping the loops easy to transfer tubing through.
Transfer tubing from the decoiler through loops until there is enough
tubing to 󶈵ll the 󶈵nal bay and make the run back to the manifold using the
second set of drilled holes.
Once the 󶈵nal bay is installed, transfer tubing from coil to 󶈵ll next bay and
so on.
Tubing can be installed into Traks using a rubber mallet or
a palm hammer with a medium plastic tip.

Climate Trak / Heat Transfer Plate System Installation
17 of 40
IM-HC 530590 0621 Climate Trak (EN)
Continue transferring the tubing through the loops, 󶈵nishing one bay at a
time.
4.6 Post-Installation Tips - Insulation
Insulation should always be used in a staple-up radiant installation. Ideally
there should a 1" to 2" air gap in between the insulation and the Traks/
Plates.
However, the air gap should only be left if that space is considered a
dead air space (absolutely no air current through it, whether it be from an
outside wall, from below, or through holes in the sub󶈶oor).
To create a dead air space, begin by insulating the outside ends of the
joist bays with a separate piece of insulation (insulation blocking) between
the top of the foundation and the bottom of the sub󶈶oor to keep cold air
from entering through sills and outside walls.
Any air current through this space will decrease the performance of the
system and the insulation. By insulating outside walls, sealing any large
gaps in the sub󶈶oor, and ensuring that the insulation is tight against
the joist, this will create a situation where the air gap is bene󶈵cial to the
performance of the system.
If a dead air space is unable to be achieved, then the insulation should be
pushed up lightly against the Traks/Plates.
When using expanding foam insulation on and around
the PEX tubing, please contact the manufacturer of the
foam or Viega for PEX compatibility issues. Some foams
my cause excessive heat if installed improperly. This
excessive heat may cause damage to the PEX.
B
Fr om Decoiler
To Manifold
Inside Wall
Outside Wall
Insulation Blocking

Piping and Controls
18 of 40 IM-HC 530590 0621 Climate Trak (EN)
In many applications either an Injection or Mixing Station can be used;
however, because a staple-up system generally uses 10-20° higher water
temperature, Viega recommends only using a Mixing Station with this
type of application.
Mixing Station includes:
2 - Ball valves
1 - Pump (low, medium, high)
1 - Diverting valve with integrated high temp. limit
2 - 6⅝" Spacing mounting brackets
Options:
■ Two position actuator
■ Three position actuator
1¼" Stainless Manifold includes:
2 - 6⅝" - Spacing brackets (for compact remote mounting)
2 to 12 - Outlets per header
2 to 12 - Balancing valves on supply header for 󶈶ow adjustment from
0-2 GPM
2 to 12 - Shut-o󶈴 valves on return header designed to receive
powerheads (15061)
Built-in purge valves and air bleeders
1¼" Union Connections
1" NPT removable end caps
Other Manifolds available:
■ 1¼" Stainless Manifold Shut-O󶈴/Balancing/Flow Meters
■ 1¼" Stainless Manifold Valveless
■ 1" Brass Manifold (when using the brass manifold, an accessory kit is
needed for proper air elimination and purging)
Options:
■ Powerheads
■ Circuit temperature gauges (used with Stainless Shut-O󶈴/Balancing/
Flow Meters only)
■ SVC circuit 󶈶ow meters
■ SVC circuit ball valves
■ Reducers for direct station attachment (needed for stainless manifolds only)
5 Piping and Controls
5.1 Mixing Station and Manifolds
It is important to use Te󶈶on tape and thread sealant paste
on all connections without gaskets.
Reducers

Piping and Controls
19 of 40
IM-HC 530590 0621 Climate Trak (EN)
5.2 Radiant Systems
The Basic Heating Control is selected to modulate system water
temperature as the outdoor temperature 󶈶uctuates. Multiple zones may
be incorporated by adding Thermostats and a Zone Control.
Material Quantity Stock Code
Mixing Station 1 12120 - 12125
Basic Heating Control 1 16015
Indoor Sensor 1 16016
Three Position Actuator for Station 1 18003
1¼" Stainless Manifold, # Outlets* 1 15900-910
* Based on job requirements
Table 5: Radiant System Materials
Primary Loop Sizing*
Copper Pipe Size
(in)
Flow Rate
(GPM)
Heat Carrying Capacity
(BTU/hr)
¾4 40,000
1 8 80,000
1¼14 140,000
1½22 220,000
2 45 450,000
* Flow Rate and Heat Carrying Capacity calculation based on a 20°F temperature drop across
the system.
Table 6: Primary Loop Sizing
B.H.C
All schematics are conceptual. The designer must
determine whether this application will work in the system
and must ensure compliance with national and local code
requirements. Boiler trim (expansion tank, 󶈵ll valve, relays,
etc.) supplied by others.

Piping and Controls
20 of 40 IM-HC 530590 0621 Climate Trak (EN)
5.2.1 Single Temperature Radiant System with Boiler Modulation and Optional DHW Control
The Advanced Heating Control incorporates low temperature mixing,
provides boiler modulation, and the option of domestic hot water control
with priority.
Optional DHW sensor may be in tank or on outlet piping. If boiler and
DHW control are not needed, refer to Basic Heating Control diagrams.
Material Quantity Stock Code
Mixing Station 1 12120 - 12125
Advanced Heating Control 1 16014
Indoor Sensor 1 16016
Three Position Actuator for Station 1 18003
1-1/4" Stainless Manifold, # Outlets* 1 15700 - 15710
Thermostats * 18002
Powerheads 3 15061
Optional DHW Sensor 1 16018
Transformer 24V 1 18008, 18020
* Based on job requirements
Table 7: Single Temperature Radiant System Materials
P2
S1
A.H.C
Primary Pump
Supply Sensor
System Pump
3 Position
Actuator
Supply Manifold
Return Manifold3 Position Actuator
Expansion Tank
Pressure Reducing Valve
Back Flow Preventor
Cold Water Supply
Air Eliminator