manifold technical guide - heatlink · working pressure 87 ... ®dimension b: allow for a minimum...

ManifoldTechnical Guide

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LinkHeatwww.heatlinkgroup.com

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* Ensure freeze protection of pipe. Maximum recommended glycol solution of 50% provides protection down to -29°F (-34°C).** 79200e (European version) contains 4 brackets*** 79400e (European version) has a European FIP thread

Technical Information & Manifold Comparison

Specification TwistSeal® Mini (40 mm) TwistSeal® (55 mm) Stainless Steel

Working Pressure 87 psi (6 bar) 87 psi (6 bar) 87 psi (6 bar)

Tested Pressure 232 psi (16 bar) 232 psi (16 bar) 145 psi (10 bar)

Maximum Trunk Flow Rate11 US gpm (2.5 m3/h) - 1" Gasketed Union

18 US gpm (2.5 m3/h) - 1" FIP18 US gpm (4.1 m3/h)

22 US gpm (5 m3/h) - 1-1/2" MIP

Supply & Return Piping 1" Union1" FIP

1" FIP1-1⁄2" MIP

Operating Temperature 160°F (70°C) 160°F (70°C) 160°F (70°C)

Maximum Temperature 180°F (82°C) 180°F (82°C) 230°F (110°C)

Minimum Temperature* -65°F (-54°C)* -65°F (-54°C)* 32°F (0°C)

PEX Pipe Connections

3⁄8" nominal1⁄2" nominal5⁄8" nominal

3⁄8" nominal1⁄2" nominal5⁄8" nominal3⁄4" nominal

1⁄2" nominal5⁄8" nominal3⁄4" nominal

Comparison TwistSeal® Mini (40 mm) TwistSeal® (55 mm) Stainless Steel

FeaturesBasic Kit#79202

Standard Kit

#79201Deluxe Kit

#79200Basic Kit#79401

Deluxe Kit#79400

Commercial Kit

#7940276100 Series

76200 Series

Supply End Connection 2× 1" MIP 2× 1" MIP 2× 1" FIP 2× 1" FIP*** 2× 1-1⁄2" MIP 2× 1" FIP 2× 1" FIP

Cross Tee End Connection 2× 1" Union

Isolation Valve 2 2

Cross Tee 1 2 2

Closed End Connection 2 2 2 2 2 2

Cross Tee Plugs 2 1 3 3

Manual Air Vent ✓ ✓ ✓

Automatic Air Vent ✓ ✓ ✓ ✓

Temperature Gauge 2 2 2

Hose Bib ✓ ✓ ✓ ✓ 2 2

Silicone o-ring lubricant bottle

✓ ✓ ✓ ✓ ✓ ✓

Wrench ✓ ✓ ✓

Brackets Included 2 2 2** 2 2 2 2 2

Typical Applications residential & small commercial commercial & snow melting residential & small

commercial

snow melting

automatic air elimina-tion & local filling by others

automatic air elimina-tion & local filling with-out tem-perature readings

automatic air elimina-tion, easy commis-sioning,

easy filling

automatic air elimination

& local filling by others

automatic air elimination, easy com-missioning, easy filling

large com-mercial or snow melt-

ing

Loop Control 78200 78302 & 78303 78400

Maximum Circuit Flow Rate 1.25 US gpm (0.28 m3/h)

1.0 US gpm (0.23 m3/h)

2.5 US gpm (0.57 m3/h)

1.5 US gpm (0.34 m3/h)

2.5 US gpm (0.57 m3/h)

Balancing Return ✓ ✓

Zone Valve Balancing Return

✓ ✓

Flow Meter Balancing Return

✓

Flow Meter Balancing Supply

✓

Balancing Supply ✓

Zone Valve Supply ✓ ✓ ✓

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TwistSeal® Mini Manifold (40 mm) Configurations

#79202 Basic Assembly Kit shown with four#78200 Heavy Duty Zone Valve Supply & Balancing Return Modules

#79201 Standard Assembly Kit shown with four#78200 Heavy Duty Zone Valve Supply & Balancing Return Modules

#79200 Deluxe Assembly Kit shown with four#78200 Heavy Duty Zone Valve Supply & Balancing Return Modules and optional #56200 actuators

• 2 mounting brackets• 2 - 1" MIP supply end connections• 1 cross tee• 2 - 1⁄2" cross tee plugs• 2 closed end caps• 1 automatic air vent• 1 hose bib• 1 lube bottle × 4

• 2 mounting brackets• 2 - 1" MIP supply end connections• 2 closed end caps• 1 lube bottle

× 4

• 2 mounting brackets• 2 - 1" union cross tee end connection c/w gasket• 2 red rubber gaskets for air testing• 2 closed end caps• 1 - 1⁄2" cross tee plug• 1 thermometer pair• 1 automatic air vent• 1 manual air vent with key• 1 hose bib• 1 lube bottle• 1 wrench

× 4

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0

1

2 3

4

5

6

7

8 9

10

11

TwistSeal® Mini Manifold (40 mm) Modules

#78200 TwistSeal® Mini Deluxe (40 mm) Supply / Return Module Pair

#78302 TwistSeal® Mini (40 mm) 2 Port Zone Valve Supply & Flow Meter Balancing Return Module Pair

#78303 TwistSeal® Mini (40 mm) 3 Port Zone Valve Supply & Flow Meter Balancing Return Module Pair

Heavy Duty Zone Valve Supply Module (40 mm) Balancing Return Module (40 mm)

Note: Actuators are not to be installed “upside down” or inverted.

2 Port Zone Valve Supply Module (40 mm) 2 Port Flow Meter Balancing Return Module (40 mm)

3 Port Zone Valve Supply Module (40 mm) 3 Port Flow Meter Balancing Return Module (40 mm)

Optional 562x0 Actuator

(not included)

Balancing Settings

Flow Balancing

Valve

Flow Balancing Indicator

t

Flow Balancing Valve

Flow Meter SettingsTop View

Flow MeterOptional 562x2 Actuator

(not included)

Manual Shut-off

Manual Shut-off

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TwistSeal® Mini Manifold (40 mm) Dimensions

Note:

Minimum depth is 3-3⁄4" (96 mm) c/w actuator.

Dimension B: Allow for a minimum of 6" (150 mm) clearance from top of manifold to frame opening for StatLink® Module rough in.

Dimension C: Allow for a minimum of 6" (150 mm) clearance from the supply/return end connections to the side frame for supply/return piping that turns up or down. If straight supply/return piping is used, allow for a minimum of 12" (300 mm) or if zone valves are used, a minimum of 18" (450 mm). Be aware that the minimum distance will vary according to the supply/return piping arrangement.

Width dimensions below do not include isolation valve & necessary fittings for connection.

Number of Loops 2 3 4 5 6 7 8 9 10

Dimension A 79200 Deluxe Kit

8-7⁄8" (224 mm)

11-1⁄8" (282 mm)

13-3⁄8" (340 mm)

15-3⁄4" (398 mm)

18" (456 mm)

20-1⁄4" (514 mm)

22-1⁄2" (572 mm)

24-7⁄8" (630 mm)

27" (688 mm)

Dimension A79201 Standard Kit

9-7⁄8" (249 mm)

12-1⁄8" (307 mm)

14-3⁄8" (365 mm)

16-5⁄8" (423 mm)

19" (481 mm)

21-1⁄4" (539 mm)

23-1⁄2" (597 mm)

25-7⁄8" (655 mm)

28" (713 mm)

Dimension A 79202 Basic Kit

7-1⁄2" (190 mm)

9-3⁄4" (248 mm)

12" (306 mm)

14-3⁄8" (364 mm)

16-5⁄8" (422 mm)

18-7⁄8" (480 mm)

21-1⁄4" (538 mm)

23-1⁄2" (596 mm)

25-3⁄4" (654 mm)

06

8

10

1

7

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°C

7080

90100 110 120 130

140150

160

0

50

40 °F

2030

40 50

6070

8010

1-1⁄8"(28 mm)

2-5⁄16"(58 mm)

3-3⁄16"(80 mm)

A

2-5⁄16"(58 mm) O.C.

C

B

Allow a minimum of 24" (600 mm) above finished floor

1-7⁄8"(48 mm)

2-1⁄4"(57 mm)

1-7⁄8"(48 mm)

8-3 ⁄ 4

" (2

22 m

m)

O.C

.

11-11

⁄ 16"

(296

mm

) O

.C.

2-7⁄16"(61 mm)

1-5⁄8"(41 mm)

3-3⁄4" (96 mm)

14-3 ⁄ 4

" (3

74 m

m)

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TwistSeal® Mini Manifold (40 mm) Flow Control Graph

1210987654321TwistSeal® Mini (40 mm) Settings

11

1(227)

0.1(23)

5(1136)

0.5(114)

0.01(2)

0.05(11)

Mass Flow Rate in US gpm (L/h)

1 (3)

5 (15)

0.1 (0.3)

0.5 (1.5)

0.01 (0.03)

0.05 (0.15)

Pre

ssu

re D

rop

in f

t H

2O (

kPa)

10 (30)

30 (90)

Working loop flow ranges from 0.1 to 1.25 US gpm (0.38 to 4.7 L/m) for floor heating and from 1.5 to 2.5 US gpm (5.7 to 9.5 L/m) for snowmelting. Pressure drop must be closely checked when water flow is beyond the upper working range.

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TwistSeal® Mini Multiport Manifold (40 mm) Dimensions

Note:





Number of Loops 2 3 4 5 6 7 8 9 10

Dimension A 79200 Deluxe Kit

8-1⁄4"(208 mm)

10-1⁄8" (258 mm)

12-1⁄8" (308 mm)

14-1⁄8" (358 mm)

16-1⁄8" (408 mm)

18" (458 mm)

20" (508 mm)

22" (558 mm)

24" (608 mm)

Dimension A79201 Standard Kit

9-1⁄4"(233 mm)

11-1⁄8" (283 mm)

13-1⁄8" (333 mm)

15-1⁄8" (383 mm)

17-1⁄8" (433 mm)

19" (483 mm)

21" (533 mm)

23" (583 mm)

25" (633 mm)

Dimension A 79202 Basic Kit

6-7⁄8"(174 mm)

8-7⁄8" (224 mm)

10-3⁄4" (274 mm)

12-3⁄4" (324 mm)

14-3⁄4" (374 mm)

16-3⁄4" (424 mm)

18-5⁄8" (474 mm)

20-5⁄8" (524 mm)

22-5⁄8" (574 mm)

8-3 ⁄ 4

" (2

22 m

m)

O.C

.

11-11

⁄ 16"

(296

mm

) O

.C.

2-7⁄16"(61 mm)

1-5⁄8"(41 mm)

3-3⁄4" (96 mm)

06

8

10

1

7

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°C

7080

90100 110 120 130

140150

160

0

50

40

°F

2030

40 50

6070

8010

1-1⁄8"(28 mm)

5-15⁄16"(150 mm)

3-3⁄16"(80 mm)

2"(50 mm)

O.C.

CB


A

3-15⁄16"(100 mm)

1-7⁄8"(48 mm)

2-1⁄4"(57 mm)

1-7⁄8"(48 mm)

16"

(726

mm

)

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10

9876543TwistSeal® Multiport (40 mm) Settings

11

1(3.78)

0.1(0.38)

5(18.9)

0.5(1.89)

0.01(0.04)

0.05(0.19)

Mass Flow Rate in US gpm (L/min)

1 (3)

5 (15)

0.1 (0.3)

0.5 (1.5)

0.01

0.05 (0.15)

Pre

ssu

re D

rop

in f

t H

2O (

kPa)

10 (30)

30 (90)

(0.03)

TwistSeal® Mini Multiport Manifold (40 mm) Flow Control Graph

0

1

2 3

4

5

6

7

8 9

10

11

Flow Meter SettingsTop View


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TwistSeal® Manifold (55 mm) Configurations

• 2 mounting brackets• 2 - 1-1⁄4" FIP supply end connections• 2 closed end caps• 1 lube bottle• 2 cross tees c/w 3 - 1⁄2" cross tee plugs• 1 thermometer pair• 1 manual air vent with 1 key• 1 automatic air vent• 1 hose bib• 1 wrench for plastic nut

× 4

• 2 mounting brackets• 2 - 1-1⁄2" MIP supply end connections• 2 closed end caps• 1 lube bottle• 2 cross tees c/w 3 - 1⁄2" cross tee plugs• 1 thermometer pair• 1 manual air vent with 1 key• 1 automatic air vent• 1 hose bib• 1 wrench for plastic nut

× 4

• 2 mounting brackets• 2 - 1-1⁄4" FIP supply end connections• 2 closed end caps• 1 lube bottle

× 4

#79402 Commercial Assembly Kit shown with four#78400 Heavy Duty Zone Valve Supply & Balancing Return Modules

#79400 Deluxe Assembly Kit shown with four#78400 Heavy Duty Zone Valve Supply & Balancing Return Modules

#79401 Basic Assembly Kit shown with four#78400 Heavy Duty Zone Valve Supply & Balancing Return Modules

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Components of TwistSeal® Manifold (55 mm) Modules

Heavy Duty Zone Valve Supply Module (55 mm)

international patents

international patents

Balancing Return Module (55 mm)

#78400 TwistSeal® Deluxe (55 mm) Supply / Return Module Pair

Balancing Settings

Flow Balancing

Valve

Flow Balancing Indicator

Optional 562x0 Actuator

(not included)

Manual Shut-off

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Note:





Number of Loops 2 3 4 5 6 7 8 9 10 11 12

Dimension A79400 Deluxe Kit

9-7⁄8" (250 mm)

12-1⁄4" (310 mm)

14-5⁄8" (370 mm)

17" (431 mm)

19-3⁄8" (491 mm)

21-3⁄4" (551 mm)

24-1⁄8" (612 mm)

26-5⁄8" (672 mm)

28-7⁄8" (732 mm)

31-1⁄4" (793 mm)

33-5⁄8" (853 mm)

Dimension A79401 Basic Kit

7-1⁄2" (190 mm)

9-7⁄8" (250 mm)

12-1⁄4" (310 mm)

14-5⁄8" (371 mm)

17" (431 mm)

19-3⁄8" (491 mm)

21-3⁄4" (552 mm)

24-1⁄8" (612 mm)

26-5⁄8" (672 mm)

28-7⁄8" (733 mm)

33-5⁄8" (793 mm)

Dimension A79402 Commercial Kit

10-7⁄8" (275 mm)

13-1⁄4" (335 mm)

15-5⁄8" (395 mm)

18" (456 mm)

20-3⁄8" (516 mm)

22-3⁄4" (576 mm)

25-1⁄8" (637 mm)

27-5⁄8" (697 mm)

29-7⁄8" (757 mm)

32-1⁄4" (818 mm)

34-5⁄8" (878 mm)

TwistSeal® Manifold (55 mm) Dimensions

8-3 ⁄ 8

" (2

12 m

m)

O.C

.2-3⁄8"

(60 mm)2-3⁄8"

(60 mm)

A

1-3⁄8"(35mm)

11-11

⁄ 16"

(297

mm

) O

.C.

B

4-1⁄4"(56 mm)

2-3⁄8" (60 mm) O.C.1-11⁄16"(43 mm)

4-3⁄8" (110 mm)


C

1-5⁄16"(34mm)

2-5⁄16"(59mm)

14-5 ⁄ 8

" (5

75 m

m)

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TwistSeal® Manifold (55 mm) Flow Control Graph

1210987654321TwistSeal® (55 mm) Settings

11

1(227)

0.1(23)

5(1136)

0.5(114)

0.01(2)

0.05(11)

Mass Flow Rate in US gpm (L/h)

1 (3)

5 (15)

0.1 (0.3)

0.5 (1.5)

0.01

0.05 (0.15)

Pre

ssu

re D

rop

in f

t H

2O (

kPa)

10 (30)

30 (90)

(0.03)


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Stainless Steel Manifold Dimensions

Note:




Width dimensions below do not include necessary fittings for connection.

Number of Loops 2 3 4 5 6 7 8 9 10 11 12

Dimension A10-3⁄4"

(275 mm)12-3⁄4"

(325 mm)14-3⁄4"

(375 mm)16-3⁄4"

(426 mm)18-3⁄4"

(476 mm)20-3⁄4"

(528 mm)22-3⁄4"

(578 mm)24-3⁄4"

(630 mm)26-3⁄4"

(680 mm)28-3⁄4"

(730 mm)30-3⁄4"

(780 mm)

C


3-1 ⁄ 8

"(8

0 m

m)

O.C

.

B

12-5 ⁄ 8

" (3

20 m

m)

O.C

.

13-1 ⁄ 2

" (3

44 m

m) 2"

(50 mm)O.C.

76100 Series 76200 Series

3-1⁄2"(88 mm)

7-7 ⁄ 8

" (2

00 m

m)

O.C

.

2-3⁄16"(55 mm)

1-3⁄16"(30 mm)

A

3⁄4" AGthread

ASMEthread

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76100 Series Friction Head Graph

10.50.25Stainless Steel Manifold # of turns from closed position

0.75

1(3.78)

0.1(0.38)

5(18.9)

0.5(1.89)

0.01(0.04)

0.05(0.19)


1 (3)

5 (15)

0.1 (0.3)

0.5 (1.5)

0.01

0.05 (0.15)

Pre

ssu

re D

rop

in f

t H

2O (

kPa)

10 (30)

30 (90)

(0.03)

1.5

2

2.5

3

3.54.5


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Note: 1 kPa = 0.335 ft H2O 1 psi = 6.897 kPa 1 ft H2O = 2.985 kPa 1 US gpm = 227.16 L/h 1 kPa = 0.145 psi 1 psi = 2.309 ft H2O 1 ft H2O = 0.433 psi 1 L/h = 0.0044 US gpm

76200 Series Friction Head Graph

10.50.25Stainless Steel Manifold # of turns from closed position

0.75

1(3.78)

0.1(0.38)

5(18.9)

0.5(1.89)

0.01(0.04)

0.05(0.19)


1 (3)

5 (15)

0.1 (0.3)

0.5 (1.5)

0.01

0.05 (0.15)

Pre

ssu

re D

rop

in f

t H

2O (

kPa)

10 (30)

30 (90)

(0.03)

1.5

2

2.5

3

3.54.5

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TwistSeal® Assembly Guidelines & Maintenance

TwistSeal® & TwistSeal® Mini Manifold Maintenance

The following maintenance should be performed on an annual basis.1. Inspect the system for leaks and erosion of metal/plastic components.2. Retighten plastic nuts as needed.3. Water analysis (i.e. check corrosion inhibitor and/or glycol levels).At 10-year intervals the Shut-off Shaft Assemblies in the supply manifold and the O-ring in the return manifold should be replaced.

TwistSeal® & TwistSeal® Mini Manifold General Assembly Guidelines

Please review the instructions and warranty carefully. Assembly and installation are the installer’s responsibility and beyond HeatLink’s control. Therefore, HeatLink exclusively limits its warranty to the repair or replacement of a defective TwistSeal® manifold for up to 18 months.

10. Retighten the plastic manifold nuts after the first week of system operation.

11. The ports on the cross tee are straight threads. Tightening an NPT threaded fitting into these ports can cause the tee to crack if overtightened. For pressure testing use Pressure Test Kit #79935. Only TwistSeal® Manifold accessories with o-rings should be used on the cross tee ports.

12. When installing zone drive motors on the supply manifold, the red shut off cap must be removed.

13. Manifolds are not to be installed upside down. Multiport Modules are also not to be installed sideways.

14. Do not use TwistSeal® Mini manifolds and accessories for purposes other than those for which they were designed. Do not exceed their specifications. Failure to follow these guidelines or the product’s instructions will void the warranty.

15. In case a leak develops during testing, remove pressure from system, clean the o-ring, and reapply silicon lube.

16. A water analysis is recommended for every installation site. For warranty claims a water analysis is mandatory.

17. Consult with your HeatLink® dealer or distributor if you have any questions regarding the operations and limits of HeatLink products. Review all instructions and warranty information carefully.

1. Assemble the manifold under clean conditions. Any dirt on the o-rings may compromise seal. Ensure the o-rings are clean.

2. Use hand tightening only to connect manifold components. Use of wrenches are permitted on cross tee accessories, but do not overtighten o-rings. To tighten manifold nuts use only the manifold nut wrench.

3. Brace or support the supply and return mains parallel to the manifold and centered with the manifold’s inlet and outlet. This will prevent stress and possible damage on the manifold supply and return end connections.

4. For module balancing, refer to the settings recommended by the Design Suite HeatLoss Analysis. For multiport module (78300 series) balancing, see page 24.

5. When assembling do not crossthread manifold components.

6. Use precautions when soldering or applying heat within 16" of any manifold component.

7. Use ball valves in front of manifold for servicing requirements.

8. Prevent aggressive substances from coming into contact with the TwistSeal® Mini manifold and its accessories. This warning includes, but is not limited to, thread sealants, leak check compounds, bug sprays, lubricants, strong cleaning solvents, paints, bleaches, fluxes, etc. (see also INFO 24). However, pipe dopes and Teflon tape are permitted for use on FIP supply end connections. No tape or dope is needed where a gasket seal is provided.

9. Protect the manifold during all phases of construction using a polyethylene sheet or an enclosure.

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Stainless Steel Manifold General Assembly Guidelines

Please review the instructions and warranty carefully. Assembly and installation are the installer’s responsibility and beyond HeatLink’s control. Therefore, HeatLink exclusively limits its warranty to the repair or replacement of a defective HeatLink Manifold for up to 18 months.

Stainless Steel Assembly Guidelines & Maintenance

1. Assemble the manifold under clean conditions. Any dirt on the o-rings may compromise the seal. Ensure the o-rings are clean.

2. Brace or support the supply and return mains parallel to the manifold and centered with the manifold’s inlet and outlet. This will prevent stress and possible damage on the manifold supply and return end connections.

3. Use precautions when soldering or applying heat within 16" of any manifold component.

4. Ball valves in front of manifold are for isolating the manifold in case of servicing requirements.

5. Prevent aggressive substances from coming into contact with the manifold and its accessories. This warning includes, but is not limited to, bug sprays, lubricants, strong cleaning solvents, paints, bleaches, fluxes, etc. However, pipe dopes and Teflon tape are permitted for use on FIP supply end connections. No tape or dope is needed where a gasket or o-ring seal is provided.

6. Protect the manifold during all phases of construction using a polyethylene sheet or a permanent HeatLink manifold enclosure.

7. The ports on the manifold are straight threads. Tightening an NPT threaded fitting into these ports can damage the manifold. For pressure testing use Pressure Test Kit #79935. Only HeatLink Manifold accessories should be used on the manifold ports.

8. When installing actuators on the return manifold, the black shut off cap must be removed.

9. Manifolds are not to be installed upside down.

10. Do not use HeatLink Stainless Steel Manifolds and accessories for purposes other than those for which they were designed. Do not exceed their specifications. Failure to follow these guidelines or the product’s instructions will void the warranty.

11. In case a leak develops during testing, remove pressure from system before servicing the effected component.

12. A water analysis is recommended for every installation site. For warranty claims a water analysis is mandatory.

13. Consult with your HeatLink® dealer or distributor if you have any questions regarding the operations and limits of HeatLink products. Review all instructions and warranty information carefully.

Stainless Steel Manifold Maintenance

The following maintenance should be performed on an annual basis.1. Inspect the system for leaks and erosion of metal/plastic components.2. Retighten nuts as needed.3. Water analysis (i.e. check corrosion inhibitor and/or glycol levels).At 10-year intervals the Shut-off Shaft Assemblies in the supply manifold and the O-ring in the return manifold should be replaced.

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18

Manifold Mounting

Manifolds are not to be installed upside down.

Manifolds and actuators may be mounted sideways. Note that the

Automatic Air Vent will not work sideways. Replace the Automatic Air Vent

with a Manual Air Vent (#79931).

TwistSeal® Mini Multiport flow meters will not work sideways.

Stainless Steel manifold flow meters will work sideways.

Supply & Return Piping

In order to prevent stress

on the manifold supply and

return end connections, the

supply piping must be braced

or supported, parallel to the

manifold and centered with the

manifold's inlet and outlet.

Install ball valves in front of

the TwistSeal® manifold for

servicing requirements.

Installation Guidelines

Brace

Brace

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TwistSeal® & TwistSeal® Mini: Number of Loops & Mounting Brackets

Installation Guidelines

The number of loops a manifold can have depends on

certain design criteria, such as, total flow to manifold

and space availability. However, close attention should

be paid to the floor temperature in the vicinity of the

manifold. Increasing the number of loops will increase

the surface floor temperature towards the supply water

temperature.

Each TwistSeal® manifold assembly kit (#79200 &

#79400 series) contains 2 mounting brackets which

will support up to 5 loops and cross tee. Additional

mounting brackets should be added when the number

of loops is greater than 5, see Table to the left.

Brackets should be placed as close to ends of the

manifold as possible and the additional brackets should

be spaced as evenly as possible. Manifold cross tees

(55 mm) must be supported by a bracket.

Number of Loops

Number of Brackets Required

TwistSeal® Mini (40 mm)

TwistSeal®

(55 mm)

2 2 2

3 2 2

4 2 2

5 2 2

6 3 3

7 3 3

8 3 3

9 4 3

10 4 4

11 4 4

12 5 4

13 5 5

14 5 5

15 6 5

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20

TwistSeal® General Assembly Instructions

Closed End Cap

Balancing Return Module

Union Cross Tee End

Connection with

Automatic Air Vent & Hose Bib

Union Cross Tee End

Connection with Manual

Air Vent & Plug

TwistSeal® Mini (40 mm) Deluxe Assembly Kit (#79200) withTwistSeal® Mini (40 mm) Deluxe Zone Valve Supply & Balancing Return Modules (#78200)

For both the supply & return manifolds:1. Twist the desired number of modules together.2. Twist on the closed end cap and end connection.3. Screw in applicable cross tee accessories (e.g. air vents, thermometers, hose bib, plugs, etc.).4. Snap the assembled manifold into the mounting brackets.

Note: When assembling the manifold, ensure the o-rings are clean.

Closed End Cap

Zone Valve SupplyModule

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PEX Pipe to Stainless Steel Manifold Connection using #77100 Series Connectors

1. Lubricate the inside of the manifold port with silicone

o-ring lubricant (#79952).

2. Cut the PEX pipe at a 90° angle.

3. Place the Nut and Split Ring Ferrule onto the PEX pipe.

Method A

5. Push the Brass Insert onto the PEX pipe as far as it will

go.

6. Push the PEX pipe with Brass Insert as far as it will go

into the manifold module. Ensure the o-ring is clean and

take care not to pinch it.

Method B (illustrated)

5. Push Brass Insert as far as it will go into the manifold.

Ensure the o-ring is clean and take care not to pinch it.

6. Push PEX pipe onto the Brass Insert as far as it will go.

7. Use a wrench to tighten the nut.

90°

Brass Insert with O-ring

Split Ring Ferrule

Nut

Pipe to Manifold Connections

Description Stk. # Qty.

SS Manifold Port Cap 77100 10 pair

1⁄2" Manifold Connector for SS manifold 77105 10 pair



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1. Remove Plastic Manifold Nut from Manifold Module.2. Lubricate the inside of the manifold port with silicon

o-ring lubricant (#79952).3. Cut the PEX pipe at a 90° angle.4. Place the Plastic Manifold Nut, Cone Ring, and Split

Ring Ferrule onto the PEX pipe (the bevelled edge of the Cone Ring must be facing the Split Ring Ferrule).

Method A5. Push the Brass Insert onto the PEX pipe as far it will

go.6. Push the PEX pipe with Brass Insert as far as it will go

into the manifold module. Ensure the o-ring is clean and take care not to pinch it.

Method B (illustrated)5. Push Brass Insert as far as it will go into the manifold

module. Ensure the o-ring is clean and take care not to pinch it.

6. Push PEX pipe onto the Brass Insert as far it will go.

7. Use the multi-purpose wrench to tighten the nut. To prevent overtightening, the wrench is designed to slip when the nut is tight.

Brass Insert

with O-ring

Split Ring Ferrule

Cone Ring

Plastic Nut

90°

Description Stk# Qty3⁄8" PEX pipe to manifold connector 77012 10 pair

1⁄2" PEX pipe to manifold connector 77005 10 pair

5⁄8" PEX pipe to manifold connector 77019 10 pair

3⁄4" PEX pipe to manifold connector including nut 77022 10 pair

PEX Pipe to TwistSeal® & TwistSeal® Mini Manifold using #77000 Series Connectors

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Method B for 3⁄4" Crimp and SS Clamps1. Remove Plastic Manifold Nut from Manifold Module.2. Lubricate the inside of the manifold port with silicone

o-ring lubricant (#79952).3. Push the Plastic Crimp Insert (23000 Series) as far as

it will go into the manifold module. Ensure the o-ring is clean and take care not to pinch it.4. Screw the Plastic Nut back on using the multi-

purpose wrench. To prevent overtightening, the wrench is designed to slip when the nut is tight.

5. Cut the PEX pipe at a 90° angle. 6. Using a Crimping Tool or SS Clamp Tool, the PEX

pipe can now be crimped onto the Crimp Insert with a Crimp Ring or SS Clamp. Avoid sideways motion during crimping to reduce stress on the fitting and manifold. For Crimp Rings, use a Crimp Gauge (#11100) to check that the connection is tight enough .

Method A for 1⁄2" Crimp1. Cut the PEX pipe at a 90° angle. 2. Remove Plastic Manifold Nut from Manifold Module.3. Place the Plastic Nut and a Crimp Ring onto the PEX

pipe.4. Using a Crimping Tool, the PEX pipe can now be

crimped onto the Crimp Insert with a Crimp Ring. Use a Crimp Gauge (#11100) to check that the connection is tight enough.

5. Lubricate the inside of the manifold port with silicone o-ring lubricant (#79952).

6. Push the Plastic Crimp Insert (23000 Series) as far as it will go into the manifold module.

Ensure the o-ring is clean and take care not to pinch it.7. Screw the Plastic Nut back on using the multi-

purpose wrench. To prevent overtightening, the wrench is designed to slip when the nut is tight.

Description Stk# Qty3⁄8" crimp insert; plastic 23012 5

1⁄2" crimp insert; plastic 23015 5

3⁄4" crimp insert including nut; plastic 23032 5

PEX Pipe to TwistSeal® & TwistSeal® Mini Manifold using #23000 Series Crimp Connectors

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Balancing TwistSeal® Multiport Manifolds

• Remove all supply caps and actuators during flow balancing procedure to allow for full open.

Balancing Method 1:Valve setting or flow characteristic known (pre-balancing)1. Fully open the supply valves (remove white caps or

actuators)2. Turn the blue cap to adjust the return valve to the desired

setting per the heatloss calculation or friction head graph.3. After all valves are set, field adjustments may be necessary.4. Setting the limit (optional) - Pull up the white limiter ring and

turn it clockwise until the white “stop” butts up against the blue triangle. Push the white limiter ring down to lock it in place.

Note:• Horizontal mounting only (as shown); flow meter will not function sideways or upside-down.• Valves are shipped open (valve at setting 11, white limiter ring at setting 11).• Clean and lubricate o-rings before assembly.• The white limiter ring allows for easy “off” / “balanced-on” of loops without having to recalibrate the manifold.

Balancing Method 2:Only flow rate known1. Fully open the supply valves (remove white caps or

actuators).2. Turn the blue cap to adjust the flow to the desired setting

(flow meter).3. Valves adjusted first may need to be re-adjusted once all

other loops have been set.4. Setting the limit (optional) - Pull up the white limiter ring and

turn it clockwise until the white “stop” butts up against the blue triangle. Push the white limiter ring down to lock it in place.

Please note:Do not use tools to adjust flow meters. (Damage to the flow meter will occur, and will not be covered under warranty).

Supply

Return

Bold Italic numbers are relative to the black manifold body arrow.

Valve Setting = 11Limit = 11

Example: Setting 6

Valve Setting = 6 Limit = 11

Valve Setting = 6 Limit = 6

UP

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➀

➀

Supply ManifoldSecondary Balancing (Fine Tuning).

CCW = open CW = closeCCW = open

CCW = open

CW = close

CW = close

Return ManifoldPrimary Balancing.

Black cap for manual shut-off only.Use drip cap ➀ for balancing.

Balancing Method 1:Valve setting or flow characteristic known (pre-balancing)1. Fully open supply valve (flow meter) [factory open].2. Close return valve completely [factory open].3. Open return valve the number of turns as per heatloss calculation or

friction head graph.4. After all valves are set, field adjustments may be necessary.

➁

➀

Notes:• Hose bib thread is an ASME thread.➁• After fill procedure: the drip cap ➀

should be placed back on to the hose bib ➁.

• Pipe to manifold connectors sold separately.

Balancing Method 2:Only flow rate known1. Ensure all supply valves are open [factory open].2. Ensure all return valves are open (remove black cap).3. Use the return valve to adjust flow to desired setting (flow meter).4. Valves adjusted first may need to be re-adjusted once all other loops

have been set.

Remove locking cap to adjust flow meter.

Please note:Do not use tools to adjust flow meters. (Damage to the flow meter will occur, and will not be covered under warranty).

Balancing Notes:Return : Use for primary balancing purposes and manual shut-off. Use drip cap to adjust the return manifold. Caution: Opening the return valve too far will result in removing the valve stem.Supply : Use for secondary balancing / fine tuning the flow rate. Remove locking cap to adjust the flow meter by

hand, do not use tools.

76100 Series

76200 Series

76100 & 76200 Series

Flow meter balancing adjustment range: 0-1.5 US gpm or 0-5 L/min.

Balancing the Stainless Steel Manifold

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TwistSeal (55 mm O.D.) Generic Specification

Provide factory pre-fabricated high impact plastic (PSU/PPA) manifolds for all distribution requirements. Manifolds modules to be capable of disassembly and reassembly for service and modification. Supply modules to incorporate an integral manual shutoff for loop isolation and allow for electric actuator and thermostat operation. Return modules to incorporate an integral manual shutoff for loop isolation and balancing of the flow rate on each loop. Individual modules to be capable of accepting 3⁄8", 1⁄2", 5⁄8" or 3⁄4" PEX pipe. Manifolds shall come complete with factory designed and supplied mounting brackets, thermometers, air vents, hose bib, end caps and supply adapters. Supply adapters will be 1" FIP or 1-1⁄2" MIP brass. Manifold assembly temperature and pressure ratings to meet or exceed the following: Working pressure: 87 psi (6 bar) Test pressure: 232 psi (16 bar) Operating Temperature: 160° F (70°C) Maximum Temperature: 180° F (82°C)

Manifolds shall be TwistSeal (55 mm O.D.) manifolds by HeatLink or approved equal.

PEX pipe connection to each module to be of brass, complete with compression ring and insert barb with o-ring capable of removal for service and modification.

Sample Specification & Layout

Sample Room Layout

Minimum 24" from Floor to Manifold

Concrete topping

Tracking

Conduit Elbows

Isolation Valve

Supply Module (Red)

Compression Fitting Nut

Mounting Bracket

Flow Balancing Valve

Return Module (Blue)

28mm PEX to act as sleevethrough control joint for

150mm either side of joint

Sub-Floor

1/2" Oxy-Barrier PEX

Front View

Side View

Manifold 24 loops total

28-312"296ft12T6

ManifoldLoop #SpacingLengthSettingThermostat

28-412"274ft12T6



28-112"275ft12T6


28-212"273ft12T6

This room layout is an example of the CADD drawings that are done by HeatLink’s design department.

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1. The gauge is recommended for air tests; take appropriate measure to prevent corrosion if using for hydrostatic tests; in cold environments, a hydrostatic test must be properly freeze protected before testing.

2. For the purposes of testing, replace the automatic air vent with the manual air vent. Install the pressure test gauge on the supply manifold. Caution: Gauge has a running thread with o-ring seal. Do not use dope or teflon tape on threads.

3. Sealing manifold end connections: a) TwistSeal® (55 mm): Use 1" Brass plugs with standard

thread sealant (not included). b) TwistSeal® Mini (40 mm): Use 1" Brass plugs with Red

Rubber Gaskets (1 per plug, 2 extra gaskets included). Do not overtighten (gasket can shear). Do not add dope or teflon tape to threads. Note: The fiber gasket provided with manifold assembly kit

should not be used with an air test.4. For the pressure test use: • Air pressure: 60-80 psi (415-550 kPa) • Hydrostatic pressure: 80-100 psi (550-690 kPa)[see 1.]5. This test must be performed for a minimum of 12-24 hours

before the placement of the topping.6. Special care must be taken to check and re-tighten all joints

and connections. During the pouring of the topping, the pipe must be left under pressure so that possible damage to the pipe can be immediately detected.

7. Replacement Gaskets can be ordered from HeatLink through your local wholesaler under HeatLink® Stk.# 79953.

Note: Be aware of how temperature can affect air tests. Rising air temperature increases pressure, and falling air

temperature decreases pressure.

TwistSeal® (55 mm) Deluxe TwistSeal® Mini (40 mm) Deluxe

Front Viewof Gauge

• 2 - 1" brass plugs• 4 red rubber gaskets (1 per plug, 2 extra gaskets included)• 1 pressure test assembly

Pressure Test Kit (#79935)

3a3b

2

22

L3610 © HeatLink Group Inc.Printed in Canada

June

16,

200

9


CanadaManufactured & distributed by HeatLink Group Inc.Head Office:4603E - 13th Street N.E.Calgary, Alberta, T2E 6M3Toll Free: 1-800-661-5332Phone: (403) 250-3432Fax: 1-866-450-1155Mississauga Office:1555 Bonhill Road, Unit #7Mississauga, Ontario, L5T 1Y5Toll Free: 1-800-661-5332Phone: (905) 795-8289Fax: 1-866-450-1155

ChinaDistributed by Cathay-Links International Phone: 852-25693213Fax: 852-25359271

IrelandDistributed by Jamoni Ltd. Phone: 057 - 932 4062Fax: 057 - 932 4063Freephone: 1800-311338

MéxicoDistributed by Distribuidora Caisa S.A. de C.V.Phone: (52) 3300-4400Fax: (52) 3300-4406

USADistributed by HeatLink Group Inc.Grand Rapids Office:1000 - 100th Street SW, Suite BByron Center, MI, 49315Toll Free: 1-800-661-5332Phone: (616) 877-4142Fax: 1-800-869-6098

HeatLink, StatLink, and TwistSeal are registered trademarks of HeatLink Group Inc.

manifold technical guide - heatlink · working pressure 87 ... ®dimension b: allow for a minimum...

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