Hot Water Energy Storage THE HOT WATER PEOPLE HEAT INTERFACE UNIT ENGINEERED FOR ULTIMATE HEATING COMFORT AND MAXIMUM SYSTEM EFFICIENCY

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1 Hot Water Energy Storage HEAT INTERFACE UNIT ENGINEERED FOR ULTIMATE HEATING COMFORT AND MAXIMUM SYSTEM EFFICIENCY THE HOT WATER PEOPLE

2 Hot Water Energy Storage THE HOT WATER PEOPLE Providing premium hot water and heating solutions for the house building industry KINGSPAN RANGE HOT WATER SOLUTIONS For over 85 years, Kingspan Range has been a leading manufacturer of premium quality hot water and heating products for the housing sector. We have a proven track record of bringing innovative, high performance products to the market that stand the test of time. Our commitment to achieving ever higher standards, through a programme of continued testing and product improvement is recognised by our BS EN ISO 9001:2008 accreditation. This results in Kingspan Range products being at the forefront in terms of efficiency and performance. At Kingspan Range we pride ourselves on a deep understanding of the challenges faced by house builders, developers and contractors. We have specifically developed the Kingspan Range product portfolio and support services such as Kingspan Service and Coates Design to meet all of their requirements. That s why we are the hot water people they turn to time after time for solutions to their hot water and heating needs. As one of Kingspan Environmental s premier brands, Kingspan Range benefit from the substantial backing of Kingspan Group, a global leader in high performance building products for the construction industry. The Kingspan Range brand fits within an overall philosophy of helping to deliver high efficiency, low cost and low carbon buildings for the future. CONTENTS Introduction to Hot Water Solutions 2 from Kingspan Range The benefits of choosing a Heat Interface Unit 3 Benefits for all 4 Introduction to Kingspan Range HIU s 5 Key Components - Kingspan Range HIU s 6 Dimensions and Components 7 What makes Kingspan Range HIU s 8 stand out from the crowd? Technical specification 11 2

3 KINGSPAN RANGE PREMIUM HOT WATER PRODUCTS HEAT INTERFACE UNIT PERFORMANCE When it comes to delivering what our customers want, the top priority is performance - it s key to providing maximum operating efficiencies and fast hassle-free installation. HIU s deliver heat that has been generated from a centralised heating plant to apartments. They maximise and optimise the whole system s performance to provide high levels of heating comfort in every room and copious volumes of hot water for washing, bathing and showering. PREMIUM Kingspan Range products only feature the highest quality components that are rigorously tested to ensure they provide safe, dependable hot water and heating for each dwelling. KINGSPAN RANGE HIU The Kingspan Range HIU is an ultra-high performance indirect Heat Interface Unit that provides precisely-controlled economical heating and hot water to the apartment, combined with the maximum level of control, to guarantee the lowest system return temperatures possible. This ensures a very high system operating efficiency, which in turn means lower running costs. The Kingspan Range HIU will provide the apartment with all of its heating and hot water needs. In principle, it acts as gas combi boiler without a flame or burner. All heat to run the HIU is provided by the centralised heating boiler. EXPERTISE Our team of technical experts contains a broad spectrum of skilled professions, including engineers with experience in the construction industry, accredited system designers, SAP assessors and people with practical plumbing experience. A choice of units with heating and hot water outputs to suit all types and sizes of apartments, ensures that the demand of achieving a high level of performance with maximum economy will always be satisfied. 3

4 Hot Water Energy Storage BENEFITS FOR ALL IMPROVING EFFICIENCY FOR ALL KINGSPAN RANGE PRODUCTS DELIVER EFFICIENCY GAINS FOR EVERYONE FROM THE DEVELOPER TO THE HOMEOWNER Better SAP Ratings Reduced installation costs Reduced project complexity Faster, simpler installation Option to split first and second fix Easy access design for faster maintenance No need to enter apartments for routine boiler maintenance Lower energy consumption through improved system efficiency Reduced annual boiler servicing costs compared to multiple individual boilers 4

5 KINGSPAN RANGE PREMIUM HOT WATER PRODUCTS THE HOT WATER PEOPLE PRECISE CONTROL FOR WHOLE SYSTEM EFFICIENCY Key Features Compact Design Fully Modulating for High Efficiency Plug and Play Commissioning The Kingspan Range HIU has been developed to achieve outstanding levels of efficiency and economy in the property by using a high performance control interface that also helps to optimise the whole building s heating system performance. The Proportional Integral Derivative (PID) Controller combines with the Pressure Independent Control Valve (PICV) with electric actuator and the two high performance Plate Heat Exchangers (PHE) to ensure that the system always operates at its optimum efficiency, so that heating comfort and high volume hot water performance are guaranteed, even when demands on the system fluctuate. This high level of control also ensures that very low primary system (district) return temperatures are maintained, giving substantial energy savings. INDIRECT FOR SYSTEM INTEGRITY The Kingspan Range HIU is an INDIRECT HIU which means that the two plate heat exchangers keep the secondary (apartment) heating circuits totally separate from the primary (district) heating circuits. Not only does this provide a pressure break, but also ensures that if there is a leak on the apartment heating system, the whole building system will not drain down. Hot Water Safety Tempering Feature Fast Hot Water Demand Response Time Up to 16 bar Primary System Operating Pressure Scale Reduction Feature Copious volumes of Domestic Hot Water Domestic Hot Water Priority Low District Return Temperatures Provision for Heat Meter of your choice Precise setting of Heating and Hot Water Temperatures Pressure Break via Two Plate Heat Exchangers Suitable for Single - or Two-Zone Heating Systems No Compression Joints Automatic Fault Diagnostics Easy Access to All Components for Servicing Suitable for Radiators or Underfloor Heating 5

6 Hot Water Energy Storage KEY COMPONENTS KINGSPAN RANGE HIU S PICV with Electric Actuator PID controlled proportional modulation of district supply regardless of pressure fluctuations in the district heating system. The PID Controller Uses information from various sensors within the HIU and from the room thermostat to control and optimise the flow rates and temperatures of the hot water within the system. The PID Controller is the brains of the system that ensures precise central heating and domestic hot water temperatures are maintained within the apartment, whilst at the same time ensuring that as much heat as possible is scoured from the water in the district system before it is returned. The result is that you have one of the most effective and efficient heating systems available. Diverter Valve PID controlled hot water or heating with hot water priority. Plate Heat Exchangers High capacity for ultimate performance and control. A-rated Pump PID controlled proportional modulation of apartment central heating. Hot Water Safety Valve Fail safe protection against ultra high domestic hot water temperatures. 6

7 KINGSPAN RANGE PREMIUM HOT WATER PRODUCTS THE HOT WATER PEOPLE DIMENSIONS AND COMPONENTS Main components 465 Primary FLOW RETURN 1 Strainer 2 PID controller 3 PICV (behind the controller) HTG PHE 5 DHWS PHE Automatic air vent 2 7 Heating circulating pump (ErP comp.) SAFETY VALVE DISCHARGE PIPE FLOW RETURN HOT COLD FILLING LOOP 3 A 15 B 14 8 Safety valve 9 Pressure gauge 10 Flow switch Filling loop connection Thermostatic valve (high temperature limiter) 6 13 Expansion vessel C Diverter valve 7 15 Spacer for installation of heat meter 16 Bypass valve 83 Location of temperature sensors A CH flow temperature sensor B C CH return temperature sensor DHW temperature sensor Code RHIU1045 RHIU1060 RHIU1560 RHIU1570 Description Range Indirect HIU 10 Kw HTG / 45 Kw DHW Range Indirect HIU 10 Kw HTG / 60 Kw DHW Range Indirect HIU 15 Kw HTG / 60 Kw DHW Range Indirect HIU 15 Kw HTG / 70 Kw DHW 7

8 Hot Water Energy Storage THE HOT WATER PEOPLE WHAT MAKES THE KINGSPAN RANGE HIU STAND OUT FROM THE CROWD? ULTIMATE HEATING AND HOT WATER COMFORT IN THE APARTMENT - MAXIMUM EFFICIENCY AND ECONOMY FOR THE WHOLE SYSTEM. Proportional Integral Derivative (PID) Controller The PID controller with temperature and flow sensor inputs, maintains the efficiency of the HIU. It switches to DHWS on demand and maintains stable temperatures for both the HTG and DHWS, even under varying demand conditions. The PID logic is also very clever in that it is dual-speed, which means that it reacts to demand by accelerating or decelerating response, to achieve and stabilise the set point quickly. Pressure Independent Control Valve The integral PICV with electric actuator gives proportional modulating control, as instructed by the PID Controller, with 100% authority, regardless of pressure fluctuations in the primary (district) heating supply. Unlike many other HIUs, no further control valves are required to achieve this. Anti-Scale Device To reduce the potential for scale to build up in the DHWS PHE, the flow is always diverted away from the DHWS PHE and into the HTG PHE when there is no DHWS demand. Automatic Fault Diagnostics The PID controller can identify problems within the system and displays an identifying fault code on the screen. Once the problem has been rectified the control unit automatically resets and resumes normal operation. Heating Flow Limitation This function decreases the possibility of the secondary (apartment) circuit being starved of heat when extreme demands are made on the primary (district) network. For example, in cold weather when a large heating demand is made on the network, the control unit does not allow 100% opening on start up and prevents the over demand causing disruptions. 8

9 Instant Hot Water Response Immediate availability of domestic hot water from the HIU is ensured at all times, as the system is programmed to charge the DWHS heat exchanger at regular intervals. This is maintained whenever there is no DHWS demand, with the PICV periodically opening to allow a small flow of hot water into the DWHS heat exchanger. The intervals between the PICV opening and the amount of hot water let through are both adjustable to suit the application or to satisfy individual requirements, but come factory set to 3.5 litres every 20 minutes Optimised Heating Control The HTG return temperatures are constantly monitored. The PID controller uses this information to maintain the optimum flow volume and temperature, which keeps the primary (district) return temperature as low as possible. DHWS Priority DHWS is the priority operation of the HIU. A flow switch detects the demand and the HIU switches to DHWS production. The HIU will still produce DHWS, even if there is a problem on the HTG side. Low Pressure Protection A low pressure switch will stop the circulating pump should the HTG system drop below 0.7bar. The HIU is fitted with a safety relief valve set at 3 bar for high pressure protection. Underfloor Heating The Range HIU is fully compatible with low temperature underfloor heating systems. The installer simply sets the required parameter on installation. Insulation The casing panels are all fully insulated, including the back-plate, to prevent overheating of the surrounding area. Prepayment Billing This can be accommodated with an accessory kit to shut down the unit when the tenant is no longer in credit. Security The metal casing can be closed, by using the optional security fixing bolts, to prevent unauthorised tampering. High DHWS Temperature Safety An integral thermostatic limiting valve, set at 60ºC, will ensure that no extreme temperatures can pass through to any outlet within the apartment. Being a mechanical device, this safety feature is maintained even if the electric supply to the HIU is cut. 9

10 Hot Water Energy Storage IMPROVING BUILDING EFFICIENCY DESIGNING THE PRODUCTS TO DELIVER HIGH EFFICIENCY, LOW COST & LOW CARBON BUILDINGS FOR THE FUTURE UNRIVALLED TECHNICAL EXPERTISE COATES DESIGN PARTNERSHIP PROVIDING A COMPREHENSIVE CONSULTANCY SERVICE TO ENSURE YOUR SYSTEM DESIGNS ARE ENERGY EFFICIENT 10

11 TECHNICAL SPECIFICATION Technical Parameters RHIU1045 RHIU1060 RHIU1560 RHIU1570 Primary (heat supply from district heat source): Maximum Pressure 16 bar 16 bar 16 bar 16 bar Primary (heat supply from district heat source): Maximum Temperature 90 C 90 C 90 C 90 C Primary (heat supply from district heat source): Maximum Pressure Differential 4 bar 4 bar 4 bar 4 bar Secondary (apartment central heating ): Maximum Pressure 3 bar 3 bar 3 bar 3 bar Secondary (apartment central heating ): Maximum Temperature 85 C 85 C 85 C 85 C Secondary (apartment central heating): Temperature Adjustment 20 C to 85 C 20 C to 85 C 20 C to 85 C 20 C to 85 C Secondary (apartment central heating ): Heating Output 10 kw 10 kw 15 kw 15 kw Domestic Hot Water (including cold water supply main) : Maximum Pressure 10 bar 10 bar 10 bar 10 bar Domestic Hot Water: Maximum Temperature Limited by TMV 60 C 60 C 60 C 60 C Domestic Hot Water: Temperature Adjustment 30 C to 65 C 30 C to 65 C 30 C to 65 C 30 C to 65 C Domestic Hot Water: Output 45kW 60kW 60kW 70kW Cold Water Mains Supply: Recommended Minimum Pressure at inlet to the HIU 2 Bar 2 Bar 2 Bar 2 Bar Controller Factory Settings RHIU1045 RHIU1060 RHIU1560 RHIU1570 Domestic Hot Water services 55 C 55 C 55 C 55 C For Heating to radiators 60 C 60 C 60 C 60 C Main Components RHIU1045 RHIU1060 RHIU1560 RHIU1570 SECONDARY circulating pump: Wilo Yonos Para RKA - with self-venting function Pressure Independent Control Valve (PICV) Ltrs/hr Central Heating - Zilmet Plate Heat Exchanger: WRAS approved ZC315 ZC315 ZC315 ZC315 Domestic Hot Water - Zilmet Plate Heat Exchanger: WRAS approved ZC315 ZC315 ZC315 ZC315 Zilmet Expansion Vessel 13M : 8 Litre - max pressure 3 Bar Thermostatic Mixing Valve 60007CP: Factory set and locked at 60ºC Diverting Valve 3VP.SAT stroke 10mm - 100N Honeywell Flow Sensor C7195A/B Safety Valve (Secondary Room Heating) 3 bar 3 bar 3 bar 3 bar Specification Information RHIU1045 RHIU1060 RHIU1560 RHIU1570 HIU installation weight 25Kg 25.4Kg 25.4Kg 25.4Kg Connections 3/4 M 3/4 M 3/4 M 3/4 M Room thermostat Not Supplied Not Supplied Not Supplied Not Supplied Technical for Electrical RHIU1045 RHIU1060 RHIU1560 RHIU1570 Power supply Maximum power consumption 230V / 50Hz / 1PH 53W Heat Meter Installation RHIU1045 RHIU1060 RHIU1560 RHIU mm spacer pipe for heat meter Optional Accessories RHIU1045 RHIU1060 RHIU1560 RHIU1570 Flushing By-pass Valve - Part Code RFBV RFBV RFBV RFBV Ball Valve Set - 4 to suit apartment heating connections - Part Code RBVS RBVS RBVS RBVS Pre-payment Relay Kit - to isolate heating when no credit - Part Code RPRK RPRK RPRK RPRK Stand-off Brackets - to facilitate rear pipework - Part Code RSOB RSOB RSOB RSOB Security fixings for the outer case RSFS RSFS RSFS RSFS 11

12 Wakefield Office Tadman Street, Wakefield, West Yorkshire, WF1 5QU Tel.: Fax: KingspanHWSystems We take every care and precaution to ensure that information in this document is accurate at the point of publish but with continuous product development the details given in this document are subject to alteration without notice. REF: Kingspan Range - HIU - English - March 2016