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Poor Flow in Underfloor Heating System: Causes in New Construction with Air-Water Pump, 250m2 Area

marcel_76 58560 39
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Why is the flow so low in my 250 m² underfloor heating system, and should I use a stronger pump or split it into two pump circuits?

The flow is most likely limited by an undersized circulation pump and excessive hydraulic resistance from the thermostatic mixing valve, with the long loops making the problem worse [#14392819][#14392773] For your setup, one reply estimated you need about 4.5 m of head and around 3.5 m³/h, while the current Wilo Yanos Pico 25/1-6 is only a little over 1 m³/h in this application [#14392819] The suggested fixes were to replace it with a stronger model such as Wilo Stratos Pico 25/1-8 (or at least 30/1-8 if staying with this layout), and to use a low-resistance motorized 3-way valve instead of the thermostatic one [#14392601][#14392773][#14392962] If you add a second pump, it should feed the upper/lower zone separately from the buffer/boiler, not be mounted after the first pump in series, and both pumps should have check valves [#14392622] The thread also pointed out that the loops are very long—about 94 m per loop on average—so splitting the installation into separate zones for upstairs and downstairs is a sensible approach [#14393294] After removing the thermostatic valve, the original poster reported the flow improved, which supports the valve plus pump-sizing diagnosis [#14399917]
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  • #31 14400609
    saskia
    Level 39  
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    marcel_76 wrote:
    saskia wrote:
    marcel_76 wrote:
    I removed the thermostatic valve and the flow with 3 manifolds turned on is in the range of 1-1.3. When closing the lower distributor, the upper one is in the range of 1.5-1.7 and it will not perform any more. But that's definitely better than below 0.6 before disassembling the valve. How do you think to buy a second wilo pico 25 / 1-6 and divide the ground floor from the attic into two pumps or the entire installation of wilo stratos 25 / 1-8 as suggested by one of your colleagues?


    You already have all the information, the decision is up to you.

    I will wait a bit, I will see how it heats up, i.e. whether the floor heats up faster and more equally and I think that I will enter two circuits so as not to heat the bottom of the house if it is not necessary and vice versa.
    I think that you could buy a stratos 25 / 1-6 for the top power supply because it is probably more efficient than five 25 / 1-6


    The basic saving with the floor heating is to reverse the temperature system of the room "upside down", namely the heat, against gravity, remains at the bottom in the zone where the household members are. This is unhealthy in some situations, but saves you money on heating.
    With a floor heating, with warmer near the floor and colder under the ceiling, we need, for example, 18-19 ° C at a height of 1.5-1.8m, having the same thermal comfort as with radiators and 20-21 ° C. This is the main saving. If you still think that keeping the temperature at 20-21 ° C, despite the floor heating, you will use less energy, you are wrong, because 20-21 ° C for the floor heating is the same as 22-23 ° C for the radiators.
    There is no need to veer the system to max. because we have savings anyway and it's warmer at home.
    If your house has such and no other heat dissipation (insulation), then you will not exceed the energy demand in any way. neither the PC nor the fireplace will give you anything but extra costs. Lowering the operating temperature of the system means extending the operation time of pumps and controllers, and at some point further feeding of the system brings unnecessary losses instead of benefits.
    Separation of the circuits makes it easier to control room temperatures, i.e. the ground floor can only have 18 ° C at night and the floor (bedrooms) e.g. 20 ° C, and in the morning the temperature will start to change the other way around, i.e. around 7 a.m. will be identical (using both floors, some are still sleeping, others are already preparing breakfast downstairs), and over time the temperatures will change 18 ° C and less at the top, and e.g. 19-20 ° C at the bottom.
    In general, energy consumption between night and day will be the same, and only the temperature system changes between rooms-floors, depending on the location of the residents, who will hardly notice it and have thermal comfort all the time. This is what I meant in the discussion with piracik.

    There is one more detail, although explaining it is the so-called mustard after lunch, but I hope you gave the screeds and tile adhesives at least 2 weeks to dry and stabilize before putting this floor heating into operation.
    If not, you can expect cracks in various unspecified places. :-(
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  • #32 14400778
    andrzej lukaszewicz
    Level 42  
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    saskia wrote:
    The basic saving with the floor heating is to reverse the temperature system of the room "upside down", namely the heat, against gravity, remains at the bottom in the zone where the household members are. This is unhealthy in some situations, but saves you money on heating.

    It is unhealthy to overheat the floor with a floor, because the temperature distribution is just the most favorable, close to the ideal - physiological
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  • #33 14401416
    saskia
    Level 39  
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    andrzej lukaszewicz wrote:
    saskia wrote:
    The basic saving with the floor heating is to reverse the temperature system of the room "upside down", namely the heat, against gravity, remains at the bottom in the zone where the household members are. This is unhealthy in some situations, but saves you money on heating.

    It is unhealthy to overheat the floor with a floor, because the temperature distribution is just the most favorable, close to the ideal - physiological


    That's right, but with gases (ventilation) there is an unhealthy situation.
  • #34 14401694
    marcel_76
    Level 13  
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    saskia wrote:

    There is one more detail, although explaining it is the so-called mustard after lunch, but I hope you gave the screeds and tile adhesives at least 2 weeks to dry and stabilize before putting this floor heating into operation.
    If not, you can expect cracks in various unspecified places. :-(


    The spouts were lying for about half a year without heating, the tiles were also off for 2 months, so I think everything will be ok.
    I think about the second pump because in order to be able to regulate the flows without any problems, as well as when the temperature at the top or bottom drops below the set value, it is not worth heating the entire system as only a given floor can.

    I do not lower the day temperature too much from the night temperature, it is a value of the order of 1 degree. and in total, also changed, because it is at night that the controller orders to heat up the temperature to catch the 2nd tariff, i.e. the floor is heated at night to give up heat later during the day.
    Temperatures of 18 degrees are unacceptable for me - (my wife would kill me).
    The temperature in the whole house is within 21.3-22.5.


    I have mechanical ventilation with a recuperator, so this problem is also solved.
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  • #35 14401713
    jack63
    Level 43  
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    marcel_76 wrote:
    I have mechanical ventilation with a recuperator, so this problem is also solved.

    I will ask out of curiosity. What happens to the hand when the outside temperature drops below approx. -5 oC?
  • #36 14401768
    marcel_76
    Level 13  
    Posts: 141
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    jack63 wrote:
    marcel_76 wrote:
    I have mechanical ventilation with a recuperator, so this problem is also solved.

    I will ask out of curiosity. What happens to the hand when the outside temperature drops below approx. -5 oC?


    I started Reku only 2 months ago with my own design, so far there have been no anomalies in its work
    Below the display at an outside temperature of -4 degrees.
    Poor Flow in Underfloor Heating System: Causes in New Construction with Air-Water Pump, 250m2 Area
  • #37 14401827
    jack63
    Level 43  
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    marcel_76 wrote:
    I started Reku only 2 months ago with my own design, so far there have been no anomalies in its work

    Congratulations on your own design. I wonder what exchanger you used, what fans and what controller?
    I did not mean anomalies, but the possible operation of heaters to prevent the exchanger from freezing. This is a common practice in commercial trading. The controller turns on the heaters ... quietly and instead of saving we have ... payments.
    After that, you write about the outside temperature. -4 oC and the air temperature from the intake "shows": -0.8 oC ??? Could it be GWP? Although it should come out min. approx 6-8 oC.

    You did not refer to my proposal to integrate the control in one "larger" controller.
    Automation "off the shelf" is expensive and somehow works there in TYPICAL relatively simple cases. It is difficult to call your installation simple and typical, if only because of the hand.
  • #38 14401926
    marcel_76
    Level 13  
    Posts: 141
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    Rate: 123
    jack63 wrote:
    marcel_76 wrote:
    I started Reku only 2 months ago with my own design, so far there have been no anomalies in its work

    Congratulations on your own design. I wonder what exchanger you used, what fans and what controller?
    I did not mean anomalies, but the possible operation of heaters to prevent the exchanger from freezing. This is a common practice in commercial trading. The controller turns on the heaters ... quietly and instead of saving we have ... payments.
    After that, you write about the outside temperature. -4 oC and the air temperature from the intake "shows": -0.8 oC ??? Could it be GWP? Although it should come out min. approx 6-8 oC.

    You did not refer to my proposal to integrate the control in one "larger" controller.
    Automation "off the shelf" is expensive and somehow works there in TYPICAL relatively simple cases. It is difficult to call your installation simple and typical, if only because of the hand.


    The recuperator stands in an insulated attic where the temperature varies between 13 and 16 degrees. The inlet on the southern wall, on the external thermometer -4 degrees approx. 1.2 above the ground and the inlet approx. 6 meters above the ground and on a sunny day.
    Klingenburg exchanger, ebm past fans, and the control for now is also simple because a regular timer + additional bistable time relay integrated with light switches in the toilets, with time I plan to buy an alres driver, but take it easy - there are more needs.
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  • #39 14402004
    jack63
    Level 43  
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    marcel_76 wrote:
    I'm planning to buy an alres driver, but take it easy - there are more needs.

    Another driver? Are you planning a collection?
    I see you don't understand the problem of frosting on the hand. Let's leave it.
    marcel_76 wrote:
    The recuperator stands in an insulated attic where the temperature varies between 13 and 16 degrees. Air intake on the south wall,

    I do not know what an insulated attic has to an air intake if ... the hand draws in the outside air and the outside air duct is insulated?
    An insulated attic makes sense when we want ... to be warmer there than outside. However, for this to be the case, it must be heated directly or through the escape of heat from the storey below it. According to it makes no sense to me, because even with the same insulation thickness, it increases the area of heat leakage from the building, and thus its total losses.
    Not only that, it leads to problems with heating the storey under the attic.
    marcel_76 wrote:
    Klingenburg exchanger, ebm past fans, and the control is also simple for now, because it is a simple timer + additional bistable time relay integrated with the light switches in the toilets,

    I didn't mean the company, but the type of exchanger design.
    With this arrangement, I assume that there is no gravity ventilation in the house, you may have too little air exchange and / or with higher frosts completely 0!
    It seems that I am departing from the topic, but in well-insulated houses, ventilation losses can reach 50% of total heat losses, so the issue of ventilation and heating cannot be treated separately from the CO subsystem.
  • #40 21782192
    novruzsadiqov
    Level 1  
    Posts: 1
    Hi Mates,

    I have just found your discussion here and would like to hear your suggestions for my case.

    I have 170 sq.m detached 2 floor house heated by underfloor heating fully. Heat loss is about 17KW and 1100 meter 16mm PERT pipe was used. one manifold was installed on each floor, 1st floor-9 loops, 8 loops on the second floor. Now the system runs only by one circulation pump comes with combi boiler. 1st floor is generally heated better, but 2nd floor is not. There is 2-3C difference between floors. I feel that circulation pump inside combi boiler is not enough to push the hot water to the 2nd floor on 4m height. I was planning to install separate pump for each floor but 2nd floor supply line (32mm) is under floor that cant be reached now. Now I am thinking to install either one more powerful pump on the 1st floor near combi boiler with hydrulic separator to supply for the whole system or one pump on the 2nd floor just before the manifold with mixer to supply only 2nd floor. Which one do you think could be more efficient? how much power should be enough for which option? 25/6 or 25/8 ?

    I appreciate any suggestion
    Thanks

Topic summary

✨ The discussion revolves around issues related to poor flow in a newly constructed underfloor heating system covering 250m2, powered by an air-water heat pump. The system utilizes multiple manifolds and a single pump, which has raised concerns about insufficient heating, particularly on the upper floor. Participants suggest potential causes, including inadequate pump capacity, air trapped in the loops, and high flow resistance from the thermostatic mixing valve. Recommendations include venting the system, adding a second pump, and considering more efficient models like the Wilo Stratos Pico 25 / 1-8. The importance of proper loop lengths and zoning for better temperature control is emphasized, along with the need for a more sophisticated control system to optimize heating efficiency.
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FAQ

TL;DR: Homes with ~250 m² radiant floors need about 4.5 m head and 3.5 m³/h flow to keep rotameters at ≥1.5 l/min [Elektroda, piracik, post #14392819] “25 can’t do it” warns installer [Elektroda, piracik, post #14392601]

Why it matters: Correct pump sizing prevents cold rooms, high energy bills, and pump burnout.

Quick Facts

• Max recommended loop length: 50 m for Ø16 PEX to limit head loss [Elektroda, saskia, post #14393294] • Target flow per loop: 1.5–2.5 l/min for even heat [Viessmann Design Guide]. • Required pump spec here: ≥4.5 m head @ 3.5 m³/h [Elektroda, piracik, post #14392819] • Wilo Stratos PICO 25/1-8 delivers 6 m head, 4 m³/h, ~€270 (2023 retail) [Wilo Datasheet]. • Each additional meter of Ø16 PEX adds ~0.04 kPa pressure drop (30 °C water) [Uponor TechSheet].

Why do my rotameters show only 0–0.5 l/min with all manifolds open?

The Pico 25/1-6 pump provides just over 1 m³/h at 4 m head; your 1 600 m of 16 mm pipe needs roughly 3–3.5 m³/h at 4.5 m head, so the pump stalls and flow collapses [Elektroda, piracik, post #14392819]

Is one stronger pump better than adding a second pump?

Replacing the existing unit with a single 25/1-8 or Stratos PICO 25/1-8 covers the full requirement and avoids hydraulic interference between two pumps in series [Elektroda, piracik, post #14392962]

When should I use two separate pumps?

Install two pumps only if you split supply lines so each draws independently from the buffer; otherwise the downstream pump steals all flow [Elektroda, piracik, post #14392622]

What loop length is considered too long?

Anything above 50 m on 16 mm pipe raises head loss sharply; your average 94 m loops double resistance and strain pumps [Elektroda, saskia, post #14393294]

Could trapped air be the real cause?

Air can block flow; purge each loop with mains water until rotameter jumps to 2–3 l/min, as krychu57 did [Elektroda, krychu57, post #14392662] If flow still low, pump sizing is the issue.

What supply temperature suits a heat-pump floor?

Heat pumps deliver best COP at 25–32 °C supply; shutting off below 35 °C wastes efficiency and comfort [Elektroda, piracik, post #14393202]

Is night-time temperature setback worthwhile with floor heating?

Setback over 1 °C seldom saves energy because the high thermal mass must be reheated at higher supply temperatures, lowering COP [CIBSE Guide, 2022].

How do I vent each floor loop quickly?

  1. Close all manifold valves except one loop.
  2. Attach two hoses—supply to mains, return to drain.
  3. Flush until no bubbles and rotameter peaks, then move to next loop [Elektroda, krychu57, post #14392662]

What’s an edge-case failure to watch for?

In very cold weather, under-sized pumps plus long loops can let return water drop below 20 °C, risking heat-pump frosting and auto-defrost cycles that cut COP by up to 40 % [“Heat Pump Defrost”, 2021].

Which Wilo model auto-adapts to floor heating?

The Wilo Stratos PICO series with LCD display auto-adjusts Δp and shows real-time flow, making balancing easier [Wilo Datasheet].

Does mechanical ventilation affect heating load?

Yes. Ventilation can account for up to 50 % of heat loss in tight houses; ensure exchanger defrost control doesn’t activate electric heaters prematurely [Elektroda, jack63, post #14402004]
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