Viega 56160 Product Instructions

Product

Instructions

Hydronic Mixing Block

The Hydronic Mixing Block is a mixing device and boiler control, with a built in circulator and system
controller. The block can provide either a xed or reset water temperature via start/stop or constant uid
circulation. The following pages outline step by step instructions for the installation, piping/wiring, and
programming of the Hydronic Mixing Block.

Wiring Terminal Block

Pressure/Temperature Sensor

Delivery Fitting (3)

¾" Solder Connection*

Return Fitting (2)

* ProPress tailpieces may be used in place of solder connections. ProPress tailpieces are available for
sale separately. See page 5 for recommendations.

Only suitably qualied individuals with formal training in electrical and HVAC controls should attempt
the installation of this equipment. Incorrect wiring and installation will affect the warranty provided
with this unit. Wiring must be completed in accordance with the codes and practices applicable to
the jurisdiction for the actual installation.

Display Screen

Adjustment Buttons

Fitting Clip

Supply Fitting (1)

¾" Solder Connection*

Backplate

Part No 56160

The Hydronic Mixing Block is a microprocessor based controller and as such is not to be regarded
as a safety (limit) control. Please consult and install the heating or cooling appliance in accordance
with the manufacturer's recommendations.

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Instructions

Installation

1. Assemble the Hydronic Mixing Block ttings.

1

2

3

3. Once a Hydronic Mixing Block tting is fully
seated, slide the tting clip into the groove in the
port, securing the tting to the block.

1

2. Insert tting labeled “tting 1” into port labeled
“port 1” on the lower right of the Hydronic Mixing
Block. Firmly twist and press the tting until fully
seated. NOTE: Water can be used as a lubricant
on the tting o-rings and the pressure/temperature
sensor o-ring.

1

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PI-PR 566234 1218 Hydronic Mixing Block (EN)

4. Insert tting labeled “tting 2” into “port 2” on

the lower left of the Hydronic Mixing Block. Firmly

twist and press the tting until fully seated. Repeat
Step 3 to install tting clip for “tting 2.”

NOTE: this port is
plugged internally and
will not be used.

2

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5. Insert tting labeled “tting 3” into port labeled
“port 3” on the upper left. Firmly twist and press
the tting until fully seated. Repeat Step 3 to
install tting clip for "tting 3."

3

6. Attach the backplate to the wall using the four
screw mounting holes. Level the backplate.
NOTE: The backplate should be secured to a
solid backing surface such as plywood, or directly
through drywall into wall studs. Drywall anchors or
hollow wall anchors should not be used. Use at
head screws or #6 or smaller pan head screws for
mounting the backplate. If mounting directly into
wood backing, use 1" screws. If mounting through
sheet rock, use 1½" screws (screws not included).

7. Slide the Hydronic Mixing Block into the
backplate. The backplate will slide into the
grooves in the supply tting (tting 1), return tting
(tting 2) and delivery tting (tting 3).

1

8. Once the Hydronic Mixing Block has been fully

inserted into the backplate, secure it to the wall
using the two screws provided. The backplate has
two mounting points, one on each side of the

block.

Hydronic Mixing Block

mounting holes

Backplate mounting holes

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Instructions

9. Insert the wiring terminal block into the left side
of the display screen. Firmly push inwards until

fully seated.

10. To install the pressure/temperature sensor
into the delivery tting (3), rmly push down
until seated and secure with the stainless
steel sensor clip. Install clip with the lip facing
down.

3

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Instructions

* Available while supplies

last. Tailpieces are listed P

X Female union BSP.

NOTE: Make sure to disassemble the ttings before soldering. The solder cup should not be attached to the gasket or

Hydronic Mixing Block when soldering. Allow soldered ttings to cool to room temperature before re-assembly.

Part No Dimension Zero Lead *Bronze

79800 ½" x 1" X

79805 ¾" x 1" X

79810 1" x 1" X

77753 ½" x 1" *X

77758 ¾" x 1" *X

77763 1" x 1" *X

3. Connect the Delivery Fitting (tting 3) to the supply piping to the manifold.

ProPress tailpieces may be used when connecting piping to the Hydronic Mixing Block. Sold separately.

Return Fitting (tting 2) should connect to the return tee on the primary loop.

Connecting the Hydronic Mixing Block to the Primary Loop

1. Connect the Supply Fitting (tting 1) on the Hydronic Mixing Block to the supply tee on the primary loop.

2. Connect the Return Fitting (tting 2) to the return piping from the manifold. The branch connection on the

ProPress Tailpieces for Use with Hydronic Mixing Block

Step 2

Step 3

Step 1

Direction of ow

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Instructions

Wiring

Connecting to the wiring terminal block

All wiring shall be done through the wiring terminal block. The wiring terminal block has 9 terminals and should be
connected as follows:

Terminal 1,2 - Thermostat or end switch (terminal 1 and 2 can accept a dry contact or 24v powered contact)
Terminal 3,4 - Outdoor sensor
Terminal 4,5 - Boiler sensor
Terminal 6,7 - Boiler contact (TT) relay rated for 24VAC 1.0 Max AMPS
Terminal 8,9 - Internal relay rated for 24VAC 1.0 Max Amps. With the addition of a pump and boiler relay this contact can
be used for low head primary loop pump control.

Plug cord into 120 VAC Standard wall outlet (altering the cord will void the warranty).

(Dry or Powered contact)

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Hydronic Mixing Block (Terminal 1&2)

L

Hydronic Mixing Block (Terminal 1&2)

Line Voltage

Low Voltage

LEGEND: Zone Controls

Instructions

Connecting a Thermostat

Two wire with battery thermostat wiring schematic for part numbers

15116,15117,15118:

1. Connect RC terminal on thermostat to terminal 1 on the Hydronic
Mixing Block

2. Connect W terminal on thermostat to terminal 2 on the Hydronic
Mixing Block (Part number 15118 W terminal is labeled W/E)

NOTE: Thermostat batteries must be installed and working for this

conguration.

1

2

C
O
B

W

RH
RC

G
Y

LEGEND

Low Voltage

1

2

C
O
B

W

RH
RC

G
Y

Line Voltage

Three wire thermostat wiring schematic for part numbers
15116,15117,15118:

1. Connect R from the transformer to the RC terminal on the thermostat

2. Connect the C from the transformer to the C terminal on the
thermostat

3. Connect the W terminal on thermostat to terminal 1 on the Hydronic
Mixing Block (Part number 15118 W terminal is labeled W/E)

4. Connect terminal 2 from the Hydronic Mixing Block to the C terminal
on the thermostat/transformer

120 V AC

Power Supply

N

Three wire thermostat wiring schematic for part number 18050:

1. Connect R from the transformer to the R terminal on the thermostat

Class II

Transformer

C

R

2. Connect C from the transformer to C terminal on the thermostat

3. Connect W terminal on the thermostat to terminal 1 on the Hydronic
Mixing Block

4. Connect C terminal on the thermostat to terminal 2 on the Hydronic
Mixing Block

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PI-PR 566234 1218 Hydronic Mixing Block (EN)

Hydronic Mixing Block (Terminal 1&2)

1

2

120 V AC

Power Supply

N

L

Transformer

Thermostat -18050

C C R W NTC A/B

Class II

C

R

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Sensor Wiring

Installing the Outdoor Sensor

The Viega Hydronic Mixing Block includes an outdoor sensor with 10 kΩ thermistor which provides an accurate
measurement of the outdoor temperature. The Outdoor Sensor is protected by a white UV resistant ABS plastic
enclosure.

Mounting the Sensor

NOTE: The temperature sensor (thermistor) is built into the Outdoor Sensor enclosure.

1. Remove the screw and pull the front cover off the sensor enclosure.

2. Mount the Outdoor Sensor to a wall, with the wiring entering either through the back or bottom of the
enclosure. Do not mount the Outdoor Sensor with the conduit knockout facing upwards as rain could enter
the enclosure and damage the sensor.

3. The Outdoor Sensor should be mounted on a wall which best represents the heat load on the building (a
northern wall for most buildings and a southern facing wall for buildings with large south facing glass areas).
The Outdoor Sensor should not be exposed to heat sources such as ventilation or window openings.

4. The Outdoor Sensor should be installed at an elevation above the ground that will prevent accidental damage,
tampering or snow/ice build up.

Sensor with rear entry wiring Sensor with bottom entry wiring

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Instructions

1. Connect 18 AWG or similar wire to the two terminals provided in the enclosure and run the wires from the

Outdoor Sensor to terminal 3 and 4 on the wiring terminal block. Do not run the wires parallel to telephone or
power cables. If the sensor wires are located in an area with strong sources of electromagnetic interference
(EMI), shielded cable or twisted pair should be used or the wires can be run in a grounded metal conduit. If

using shielded cable, the shield wire should be connected to the Com terminal on the control and not to

earth ground.

2. Replace the front cover of the sensor enclosure.

NOTE: Maximum wire length from control to sensor is 500 ft.

Wiring connection for
outdoor sensor wires
(terminal 3 and 4)

Installing the Boiler Sensor

1. Attach wires to terminal 4,5 on wiring terminal block.

2. Run the sensor back to the supply side of the primary loop. Attach to the supply piping before the closely

spaced tees with the included zip tie. Cover the sensor with insulation for accurate reading.

NOTE: If used in BOILER AQUASTAT mode there is a choice to put sensor on the supply or return.

CONDENSING or RESET boiler modes require the boiler sensor to be installed on the supply.

NOTE: When extending sensor wires, use 18 gauge wire and do not extend over 500’.

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Instructions

Conceptual Piping Diagram

1. This drawing shows system piping concept only. Installer is responsible for all equipment and detailing required by

local codes.

2. Size primary loop piping for maximum ow velocity of 2 feet/second.

3. All other piping should be sized for a maximum ow velocity of 4 feet/second.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

5. Install isolating anges or isolating valves on all circulators.

6. Install purging valve(s) on all circuits.

7. All closely spaced tees shall be within 4 pipe diameter center to center spacing.

8. Install minimum of 6 pipe diameters of straight pipe upstream and downstream of all closely spaced tees.

9. Differential pressure bypass valve prevents ow noise under partial load conditions (some circuits closed).

10. Set differential pressure bypass valve to delta P of distribution system with all zones open +1 psi.

11. Not all components may be required depending on control strategy (i.e. constant circulation).

Piping

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Conceptual Electrical Schematic

Wiring

1. This drawing shows system wiring concept only. Installer is responsible for all equipment and detailing required by

local codes.

2. All wiring shall be in conformance with the latest edition of the National Electrical Code.

3. Maximum current rating of the Hydronic Mixing Block is 1 AMP.

4. Consult with control / boiler manufacturer for limitations and installation instructions.

5. Do not run the wires parallel to telephone or power cables. If the sensor wires are located in an area with strong

sources of electromagnetic interference (EMI), shielded cable or twisted pair should be used or the wires can be

run in a grounded metal conduit. If using shielded cable, the shield wire should be connected to the Com Sen

terminal on the control and not to earth ground. Use 18 AWG copper wiring for all sensor wiring. Sensors should

be located before the closely spaced tees.

Boiler Sensor

Primary Loop

Circulator

Mix Sensor

Outoor Sensor

Mixed Temperature

Circulator

Low Voltage

Line Voltage

Sensors

(Dry or Powered contact)

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Instructions

Programming

SETUP MENU

1. The SETUP MENU is used for entering the design
values, as well as assigning different control options
to the circulator and boiler. To access the SETUP
MENU, push the middle rectangular button

on the STATUS MENU. Use the up and down
arrow keys to scroll through the various settings.

2. To select an item, align the cursor arrow with
the item you wish to select and press the middle
rectangular button . The arrow will become solid,
which indicates that an item has been selected.

3. Once adjustment is complete, push the middle
rectangular button. This will de-select the item.

4. To go to the previous screen, select BACK and press
the middle rectangular button.

5. If the SETUP MENU is left idle for more than

90 seconds, the display will change to the

STATUS MENU and the Hydronic Mixing Block
will begin operating.

CIRCULATOR CONTROL

• OPERATION: ON/OFF — The circulator is turned on/
off as demand requires. Default is set to ON/OFF.

• OPERATION: CONSTANT — The circulator is
constantly on and will only be shut off with warm
weather shut down (WWSD). Usually used with
RESET mode.

NOTE: This function is not available with BOILER
AQUASTAT mode.

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DESIGN TEMPS

WATER TEMP CONTROL

• OUT DESIGN — Outdoor temperature used
to calculate heat loss. This temperature is based
on location and can be obtained from outdoor
design charts.
Range: -40°F to 70°F
Default: 10°F

• ROOM DESIGN — Desired room temperature used
in heat loss calculation.

Range: 35°F to 120°F
Default: 70°F

• WWSD — Temperature at which the building does
not need heat and the control will no longer activate
the circulator.

Range: 35°F to 120°F

Default: 70°F

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PI-PR 566234 1218 Hydronic Mixing Block (EN)

• TEMP CONTROL: FIXED — The control will maintain
a constant (FIXED) water temperature.

• WATER TEMP — The xed water temperature.

Range: 50°F to 180°F
Default: 120°F

• TEMP CONTROL: RESET — Water temperature will
adjust based on outdoor temperature; as the outdoor
temperature increases, the water temperature will
decrease, and vice versa. By using this type of
control strategy the output of the radiant system will
meet the load of the structure, resulting in an energy
savings for the building owner. Default: Reset

• MIX DESIGN — The design water temperature
specied by the radiant design. This is the maximum
water temperature that will be supplied.

Range: 50°F to 180°F

Default: 120°F

• MIX MIN — The minimum supply temperature for the
mixing system.

Range: 50°F to 180°F

Default: 70°F

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BOILER SETTINGS

• TYPE: RESET — This setting allows for the boiler to
change supply water temperature based on outdoor
temperatures.

• BOILER DESIGN — The water temperature needed
on design day.

Range: 70°F to 200°F
Default: 180°F

• BOILER MIN — Lowest temperature the boiler is
allowed to supply. This temperature needs to be
set high enough for the boiler to be able to maintain
mixed water temperatures.

Range: 70°F to 200°F
Default: 140°F

• BOILER DIFF — Determines turn on and shut off
temperatures. This setting will allow the boiler to
go above the boiler target by half of this setting.
Example: if the BOILER DIFF is set at 20°F, the boiler
will run until the temperature is 10°F above the boiler
target setting, and turn on when the temperature is
10° below the boiler target temp.

Range: 10°F to 50°F
Default: 20°F

• TYPE: AQUASTAT — Used when the boiler is a

non-condensing boiler that maintains its own
temperature settings. This mode is not available

with constant circulation.

• SENSOR — Installed on either SUPPLY or RETURN.

Installation must be properly identied in this setting.

• SUPPLY MIN/RETURN MIN — Minimum supply/

return temperature.
Range: 70°F to 200°F
Default: 140°F

• TYPE: CONDENSING — Used when the boiler is
a condensing boiler that maintains its own
temperature settings.

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DEFAULTS\PURGE

PURGE MODE

• F OR C — Select between FAHRENHEIT or

CELSIUS.
Default: Fahrenheit

• OVERWRITE DEFAULTS — Will allow you to change

the DEFAULTS within the control.

• RESTORE DEFAULTS — RESTORE the current

DEFAULTS.

• PURGE — Selecting this feature will bring you to

PURGE MODE.

• ACTIVATE — Will open the internal valve for 30

minutes to allow for purging.

• CANCEL — Will end the PURGE MODE, end the

timer and close the internal valve.

SETUP MENU

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PI-PR 566234 1218 Hydronic Mixing Block (EN)

• To view the STATUS screen, select BACK with the

cursor arrow in the SETUP MENU and push the
middle rectangular button.

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STATUS SCREEN

The STATUS screen shows the actual temperatures as
read by the sensors and the target temperatures the
control is trying to obtain.

• HEATING — If the display screen is red and heating

is displayed on the upper left corner of the STATUS

menu, the control is in heating mode and there is a

boiler demand. If the display screen is blue, it means

there is a heating demand but the boiler is off. If the

screen is white, there is no heating demand.

• BOIL SUP/RET — The temperature of the boiler

supply/return. This will be dictated by the sensor

location. If on the supply this will read: BOIL SUP. If

on the return it will read BOIL RET. When the boiler

sensor is bad or there is a broken/ shorted wire, it will

be represented by 5 dashes ----- in the supply field

and the control display will blink red. The block will

supply 80°F to the floor/ emitter to keep the system

from freezing.

• SYSTEM — The mixed water temperature that the

Hydronic Mixing Block will supply. This symbol: -----

present in the field means the sensor the sensor is

bad or the wire is broken or shorted.

• OUTDOOR — The outdoor temperature as read by

the outdoor sensor.

• PRESSURE — The system pressure is read by the

temperature/pressure sensor located to the left of the

display screen. The number displayed in this field is

the system pressure. If the words LOW are present in

the pressure field for one minute, the control will shut

the block down to prevent damage. If the symbol:

----- is present it indicates the sensor is bad or the
wire is broken or shorted.

• VALVE POSITION — Identifies the position of the

internal valve.

• BOILER PROTECT — If the display screen is

yellowish/green and BOILER PROTECT is present in

the lower left and right of the screen, the boiler is in

protection mode.

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Screen Color Indicator Status

Light Blue/Gray No Heat Demand

Solid Red Heat demand, boiler running

Yellow/Green Heat demand, boiler running but in boiler protection mode

Dark Blue Heat demand, boiler satised

Blinking Red

Blinking Purple PURGE MODE, will open valve for 30 min duration to allow for purging

Testing the Hydronic Mixing Block

When piping is complete, test the Hydronic Mixing Block and system piping.

1. Ensure air vent cap is tight before testing.

2. Pressurize the system to a maximum of 100 psi for one hour.

3. Once the system maintains 100 psi for one hour, carefully remove air pressure from the system and ll with uid.

Purging

When testing is complete, purge the Hydronic Mixing Block.

1. Shut the power off to the boiler.

2. Purge with only cool water, if the boiler is hot it should be cooled down prior to purging, this is done to protect
the oor coverings from surface temperatures above 85°F.

3. Plug in the Hydronic Mixing Block, allow it to run through its initial setup and bring you to the STATUS screen.

4. From the STATUS screen push the middle rectangular button.

5. DEFAULTS/PURGE

6. Select PURGE

7. Select ACTIVATE

• Selecting ACTIVATE will cause the screen to turn purple, at which time the internal valve will open, once the
valve is open the screen will blink purple and start a 30 minute timer to allow for purging

• If more time is needed, ACTIVATE may be selected as many times necessary to complete system purging

• If less time is needed purge can be cancelled by selecting CANCEL

8. Allow the Hydronic Mixing Block to be lled with uid from the supply side piping.

9. Close the valve on the return piping to the boiler.

10. Open the purge valve to allow trapped air to be eliminated.

11. Continue to allow uid to run into the block and out the purge valve until all air is removed from the system.

12. Once purging is complete, return all valves to normal operating position.

13. Open the air vent cap to allow air to escape under normal operation.
NOTE: See page 9 for piping and purge valve congurations.

14. Once the Hydronic Mixing Block, boiler and piping has been purged and properly pressurized, restart the boiler.

Failed boiler sensor or broken/shorted wire. Under this condition the block will supply 80°F uid to the

oor/emitter to keep the system from freezing

Testing the Sensors

OUTDOOR SENSOR / BOILER SENSOR

1a. Outdoor Sensor

• Use a thermometer to read the outdoor temperature.
1b. Boiler Sensor

• Use an infrared or digital thermometer to read the temperature where the boiler sensor attaches.

2. Using an ohm meter capable of measuring 10kΩ, measure the resistance present at the sensor.

3. Using the resistance chart on page 18, compare the measured temperature/ ohm reading to what is in the
chart. If reading is off by ± 5% the sensor is bad.
NOTE: Do not apply voltage to the sensors as this will damage them.

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Sensor Resistance Chart

Temperature Resistance Temperature Resistance

°F °C Ω °F °C Ω

-50 -46 490,813 90 32 7,334

-45 -43 405,710 95 35 6,532

-40 -40 336,606 100 38 5,828

-35 -37 280,279 105 41 5,210

-30 -34 234,196 110 43 4,665

-25 -32 196,358 115 46 4,184

-20 -29 165,180 120 49 3,760

-15 -26 139,402 125 52 3,383

-10 -23 118,018 130 54 3,050

-5 -21 100,221 135 57 2,754
0 -18 85,362 140 60 2,490
5 -15 72,918 145 63 2,255

10 -12 62,465 150 66 2,045
15 -9 53,658 155 68 1,857
20 -7 46,218 160 71 1,689
25 -4 39,913 165 74 1,538
30 -1 34,558 170 77 1,403
35 2 29,996 175 79 1,281
40 4 26,099 180 82 1,172
45 7 22,763 185 85 1,073
50 10 19,900 190 88 983
55 13 17,436 195 91 903
60 16 15,311 200 93 829
65 18 13,474 205 96 763
70 21 11,883 210 99 703
75 24 10,501 215 102 648
80 27 9,299 220 104 598
85 29 8,250 225 107 553

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01

Instructions

Technical Data
Input Voltage/Current

120 VAC ± 10% 60 Hz, 2A

Sensors

(2) 10kΩ - 1 boiler sensor, 1 outdoor sensor
Sensor wiring may be extended up to 500'
Use 18 gauge wire when extending

Boiler Relay

24VAC 1.0 MAX AMPS

Circulator Relay

24VAC 1.0 MAX AMPS

Microprocessor

8 Bit, 32 MHz

Fluid

Water
Propylene or Ethylene glycol to 50% concentration

Pump Curve for Hydronic Mixing Block

30

25

20

Temperature

Maximum Temperature: 203°F

Pressure

Maximum Working Pressure: 45 psi
Maximum Test Pressure: 100 psi

Weight

10 lbs.

Dimensions

12.18"W x 10"H x 6.7"D

ETL Listings

Meets CSA C22.2 No. 24
Meets UL Standard 873
ETL Control No. 3068143

Part No

56160

Dimensions

Speed 1

Speed 2

Speed 3

12.18"

4.72"

15

Head (Ft)

10

5

0

024681

Flow (USGPM)

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.

Viega LLC • 585 Interlocken Blvd. • Broomfield, CO 80021 • Phone [phone] • www.viega.us

PI-PR 566234 1218 Hydronic Mixing Block (EN)

2

10.04"

6.46"

2.46"

1.71"

2.49"

6.66"

7.72"

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