Converting 2nd-Floor TruFLOW Manifold to 6-Zone Room-by-Room Control

RTClass

I have a hydronic heating system with four zones. Two zones are B-coils tied into an AC system, and two zones serve a two-story house via Uponor TruFLOW manifolds (one manifold per floor). The system has been operating this way for about 12 years.

On the second floor, a single thermostat currently controls all heating through the manifold, with a separate thermostat for AC. The second-floor radiant system was installed without oxygen-barrier tubing, which has made material compatibility a challenge. However, the layout uses individual loops per room returning to the manifold.

There are six rooms on the second floor, each with its own loop. I’d like to convert this to room-by-room control with one thermostat per room.

I’m looking for recommendations on name-brand components and overall system approach. My assumption is that I’ll need:

• One actuator or zone valve per loop at the TruFLOW manifold (6 total)
• A controller capable of handling multiple thermostats and actuators
• A 24-V transformer or appropriate power supply
• Six 24-V hardwired thermostats (one per room)

Where I need guidance is:

• What type of controller is appropriate for this setup
• How it should be configured (logic, wiring approach)
• Which actuators/zone valves are compatible with Uponor TruFLOW manifolds
• Recommended 24-V hardwired thermostats for radiant floor heating
• Recommended 24-V hardwired programmable thermostats for radiant floor heating

Any advice on best practices—or things I should avoid given the non-oxygen-barrier piping—would be greatly appreciated.

hot_rod

A brass or stainless manifold would be options.

You would need an actuator for each zone and a relay box to power the actuators.

Keep in mind over-zoning can lead to inefficient boiler short cycling. Unless you have a buffer tank or high water content heat source, like a tank type heater?

With non barrier tube use all non ferrous components or keep an oxygen scavenger chemical in the system

Another option is a plate HX to separate the tube from the boiler and piping components.

Thermostats are pretty much personal choice. I use the basic Ecobee on my system with the ap for remote monitoring. You will need 3 wires to the stat for power consuming type thermostats.

RTClass

Thank you "hot_rod"

I should of included that I'm using Takagi t-h3-dv-n tankless hot water heater and I already have installed a Uponor TruFLOW manifold

hot_rod

Then all you need are the TruFLOW actuators and a zone valve relay box. I'm not a huge fan of tankless water heater as a heat source, but plenty of them are used like that.

Hopefully if is not providing the domestic hot water? A "combined" system