Technical and Specification Information. Greenfloor heating series GREENFLOOR HEATING VIDEO AVAILABLE ON OUR WEBSITE

Transcription

1 Technical and Specification Information Greenfloor heating series GREENFLOOR HEATING VIDEO AVAILABLE ON OUR WEBSITE

2 Worcester, Bosch Group Technical Help line Worcester and you, making a difference Working together for many years, heating professionals and Worcester have been making a real difference in hundreds of thousands of homes across the UK. We are recognised as a market leader in high efficiency, condensing boiler technology and are also committed to providing renewable energy solutions. As part of the Bosch Group, our products are designed and manufactured to provide the high levels of quality and reliability which are synonymous with the Bosch name throughout the world. We re a leading British company, employing more than 1,800 people at our headquarters and manufacturing plants in Worcester and at Clay Cross in Derbyshire, including a nationwide network of over 300 Service Engineers and over 80 technicallytrained Field Sales Managers. As part of Europe s largest supplier of heating products, Worcester, Bosch Group has the UK-based resources and support capability to offer you the value-added solutions we feel you deserve. At Worcester we recognise the vital role you, our customer, has in the specification and installation of A rated, energy efficient appliances in homes across the UK. We will continue to invest in our products, people, facilities and added value services such as training, to give you the support you require in providing a total solution for your customers comfort. Carl Arntzen, Managing Director, Worcester, Bosch Group Contents Page Worcester Greenfloor heating 4-8 Greenfloor pipe fixing methods 9 Floor constructions Greenfloor controls 12 Product compatibility 13 Installation requirements General requirements Components Specification and Design Service Greenfloor heating series components and accessories Worcester training After-sales

3 Worcester Greenfloor heating Global responsibility for nature and the environment As part of this philosophy we are proud to introduce high efficiency Greenfloor heating systems. Part of the As part of the Bosch group, Worcester is committed to Total System Solution offering from Worcester, Greenfloor environmental protection. With product development being heating systems deliver efficient heating in their own right prioritised in the interests of people s safety, the economical as well as facilitating the use of low carbon technologies use of resources and environmental sustainability. such as air source and ground source heat pumps and condensing boilers. In just a few short years, Britain s domestic heating and hot water industry has changed dramatically. Greenfloor heating is suitable for both new build and refurbishment applications, offering a number of major With approximately 25% of the UK s carbon dioxide benefits over traditional radiator systems. By operating at emissions being produced by home energy consumption, lower temperatures, underfloor heating helps to increase 75% of which is for the provision of heating and hot water, the efficiency of the boiler or heat pump and reduces such change is not only inevitable but crucial. overall running costs. Unlike radiator systems underfloor distributes heat more evenly, increasing user comfort and Words and expressions such as renewable energy, helping to reduce dust and the risk of house mites. sustainable technology and carbon footprint have become part of everyday conversation and have been Greenfloor provides a complete underfloor heating fuelled by extreme weather and stark television images package that s robust and reliable. The range includes of melting polar ice caps. PE-Xc pipe with a choice of different pipe fixing methods and manifolds for between 2 and 16 zones. These Worcester, Bosch Group, whilst continuing to satisfy the are complemented by controls and a full range of daily demands for heating and hot water comfort, has taken other accessories. a lead in developing solutions which reduce the impact on the environment by reducing CO 2 emissions not only for The pipe fixing methods are designed to make installation today but well into the future. quick and easy and can be used with traditional sand and cement screed, wet screed or as a dry construction system to suit the requirements of each property. Heat from a radiator travels up and around the walls and ceiling of a room first, losing much of its useful heat in the process......while the heat from underfloor heating is evenly distributed from the surface of the floor throughout the whole living space. Greenfloor features and benefits Features PE-Xc Pipe, protected against thermal ageing and stress fracture Pre-insulated pipe positioning panels Stainless steel manifolds Full suite of wireless and wired control systems Uses radiant heat Requires lower working temperatures Eliminates the need for radiators Complements Worcester gas- and oil-fired boilers, ground source and air to water heat pumps Benefits Flexible and durable Quick and easy installation Robust and durable Suits any type of installation Less circulation of dust than with radiators, cleaner air for home Maximises the efficiency of condensing boilers and heat pumps Creates space on walls and allows unrestricted layout within a room Complete heating and hot water solutions from one source 4 5

4 Greenfloor heating Worcester s Greenfloor heating system uses a water-filled pipe system that turns the floor into a large surface area radiator. The pipe system gently warms the space above it through a combination of radiant energy and heat conduction. In a modern, well-insulated space where heat loss factors have been taken into consideration, underfloor heating can act as the primary heating source and, in most cases, no other space heating methods will be required. Underfloor heating operates with lower water temperatures than traditional radiator systems. This makes it the perfect complement for Worcester s ground source and air to water heat pumps. As well as space heating, Worcester heat pumps are able to provide a constant supply of hot water throughout the year. The low return water temperature of underfloor heating also makes it suitable for use with Worcester condensing boilers, ensuring they remain at their optimum efficiency, with significant energy savings. As there are no radiators to take up space, Worcester Greenfloor systems also provide maximum flexibility within the property. They can also be used with a wide range of floor coverings, including parquet, carpeting, marble or tiles. Underfloor heating is a system where every component is important to overall performance. Worcester Greenfloor systems provide a comprehensive selection of high quality system components, while offering considerable flexibility to meet all of a project s needs. System components Greenfloor heating systems comprise a number of elements: PE-Xc system pipe Stainless steel manifolds Manifold cabinets Pump and mixing stations Pipe fixing methods Controls. All Greenfloor systems are supplied complete with all components and connections. Any specialist tools that are necessary are also available from Worcester. Greenfloor PE-Xc system pipe The Greenfloor PE-Xc system pipe is oxygen impermeable and highly flexible for ease of installation. The pipe is available in two sizes to suit the panel system (see table below). Pipe and pipe fixing method compatibility Pipe positioning panel 14 x 2mm 16 x 2mm Stapler panel systems 14 x 2mm 16 x 2mm Dry construction system 14 x 2mm Timber suspended floor 14 x 2mm 16 x 2mm System pipe is available in coils, with a reel available to ease unwinding, reduce waste and avoid the need for couplings. Pipe 14 x 2mm 16 x 2mm PE-Xc Yes Yes Coil length (standard) 200m 200m Coil length (long) 750m 650m Max. operating pressure 6 bar 6 bar Max. operating temperature 90ºC 90ºC Min. bend radius 70mm 80mm Greenfloor stainless steel manifolds All Greenfloor manifolds are manufactured from stainless steel and include flow meters for accurate system commissioning. A full range of accessories is available including ball valves and connectors. The pre-assembled stainless steel manifolds serve 2-16 zone applications. They are supplied with integrated valves providing a filling and draining facility and automatic air vents. In the event of additional zones being required, manifolds can be joined together. The flow rate can be accurately set on flow meters for safe and rapid setting of the values provided by the Worcester Design Service. The return manifold provides threaded connections for installation of electronic actuators. Height 350mm Depth 62mm Material Stainless steel Flow meters Yes Flow & return heat source 1" Flow & return to underfloor zones (PE-Xc pipe) 3/4" Manifold cabinets Greenfloor manifold cabinets are constructed from 1mm galvanised sheet steel. The recessed type allow a flush finish to a plastered wall and feature pre-punched side openings for manifold connections and pipe penetrations at the top and bottom. They are also height adjustable to align with the screed thickness. A surface mounted version is also available. Both the recessed and surface mounted cabinets are lockable to prevent unauthorised access. Manifold cabinets Surface VSS-A VSS-A VSS-A VSS-A mounted Width 560mm 700mm 1,000mm 1,300mm Height 700mm 700mm 700mm 700mm Depth 150mm 150mm 150mm 150mm Recessed VSS-U 560 VSS-U 700 VSS-U 1000 VSS-U 1300 Width 560mm 700mm 1,000mm 1,300mm Height (adjustable) mm mm mm mm Depth (adjustable) mm mm mm mm Note: for a two zone system, the manifold width is 200mm. For each additional zone added, the manifold width increases by 50mm. The maximum number of zones is

5 Greenfloor pipe fixing methods Greenfloor pump and mixing stations Greenfloor offers a number of pump and mixing stations to satisfy the needs of each individual installation. FRS pump and mixing station The FRS standard pump and mixing station features a fixed value thermostatic injection valve, which is commissioned on site by the installer to the specification provided by the Worcester Design Service. The flow water temperature will be maintained constantly at a safe and efficient level. The FRS also includes a high limit thermostat to protect the heated floor area from excessive temperatures using a circulating pump and temperature gauge. Each installation of an FRS will also require an FRS connection set, available from Worcester, to allow an easy and speedy connection to the Greenfloor stainless steel manifold. Alternatively, a choice of advanced controls featuring weather compensation is available. VRS pump and mixing stations The VRS weather compensated pump and mixing stations are available to suit up to both a 7kW and 10kW installation and fit directly to the Greenfloor stainless steel manifold. The VRS station features a modulating circulating pump, electronic mixing valve and an intelligent controller. This feature, through input gathered by the supplied flow temperature and outdoor sensors, adjusts the output temperature based upon external conditions. FRS standard pump and mixing station KMS pump and mixing stations The KMS remote pump and mixing stations feature the same proven components and method of operation as the VRS pump and mixing stations. The KMS provides the flexibility of mounting the station away from the Greenfloor manifold and is available to suit up to both 15kW and 25kW installations. All Greenfloor pump and mixing stations are provided with comprehensive installation, commissioning and user instructions. Further support on planning and specifying the system can be provided by the specialist Worcester Design Services team. Single room extensions The RMS pump and mixing station is designed to offer a simple underfloor heating control solution for single rooms. The RMS connects into the existing flow and return circuit of the central heating system and features a circulation pump and a temperature limiting valve on the return side. It is possible for the circulation pump to be electrically supplied via a proprietary room thermostat to provide an interlock as well as to aid energy efficiency. Please note that the RMS single room pump and mixing station relies upon the existing central heating system s controls to be calling for heat to achieve warming of the floor. To achieve a greater level of independent control, an FRS standard pump and mixing station should be selected. Greenfloor offers a range of pipe fixing methods to suit every project. Greenfloor pipe positioning panels Greenfloor pipe positioning panels are ideal for use in new and existing buildings and can be used with cement or pumped liquid screed. The channels on the panels ensure that optimum spacing of the pipe coils are achieved. Pipe is fixed using a press-stud action which enables fixing without clamps. The panels are available with and without insulation. Pipe positioning panels Light Length 900mm 900mm 900mm Width 1,447mm 1,447mm 1,447mm Depth 48mm 29mm 18mm Thermal insulation (Rλ) 0.75m 2 k/w 0.37m 2 k/w None Sound insulation 28dB None None Unit of delivery 10.4m m m 2 110mm/ 110mm/ 110mm/ Installation centres 165mm/ 165mm/ 165mm/ 220mm 220mm 220mm Greenfloor staple panels Greenfloor staple panels are easy to assemble and very cost-efficient. They are supplied as a rolled panel and manufactured from foamed polystyrene with a fully bonded, tear-proof and waterproof woven fabric coating. The imprinted installation grid allows for systemcompatible pipe spacing, as well as quick and easy pipe fixing when using our Greenfloor clip rails or staples. Greenfloor dry construction system The Greenfloor dry construction system provides the ideal solution for dry construction in buildings of all ages. They are particularly popular with timbered floors where a water-based screed is undesirable. The system is based on working with dry construction panels while using steel spreader plates into which the pipe is pressed. Easy to work with, the system enables serpentine or spiral installations and can accommodate even the most complex of room geometries. Dry construction system Panel Straight Curved plate plate Length 1,000mm 750mm 245mm Width 625mm 120mm 125mm Depth 25mm 0.5mm 0.5mm Thermal insulation (Rλ) 0.56m 2 k/w N/A N/A Sound insulation None N/A N/A Unit of delivery 13.1m 2 50 pieces 25 pieces Installation centres 125mm/ 250mm N/A Greenfloor timber suspended floor system Greenfloor clip rail and staples provide a simple cost effective solution. It is ideal for when fixing pipe to floorgrade insulation between the joists of a timber suspended floor. Tongue & groove or chipboard flooring can then be laid directly across the joists. 125mm Staple panels 35mm roll 30mm roll Width 1,000mm 1,000mm Depth 35mm 30mm Thermal insulation (Rλ) 0.78m 2 k/w 0.67m 2 k/w Sound insulation 29dB 29dB Unit of delivery 12m 2 12m 2 Timber suspended floor system Length Width Height Unit of delivery Installation centres Clip rail 1,000mm 40mm 25mm 100m 50mm 8 9

6 Floor constructions Greenfloor offers a choice of fixing methods making it suitable for all types of floor construction in new build and existing properties. It is most frequently used with ceramic, wood or laminate floor coverings, but can also be used with carpets and vinyls. Greenfloor pipe positioning panel system Greenfloor dry construction panel system underlay underlay Screed Dry screed system foil Edging insulation strip Greenfloor PE-Xc pipe Pipe positioning panel Edging insulation strip Greenfloor PE-Xc pipe Heat conducting plate Dry construction panel Concrete base Wooden floor Sub floor Greenfloor staple panel system with clip rail Greenfloor timber suspended floor system underlay Screed underlay boards Greenfloor PE-Xc pipe Greenfloor PE-Xc pipe Edging insulation strip Pipe staple Staple panel Pipe staple Concrete base Clip rail Sub floor Floor grade insulation Clip rail fixing pins Clip rail Joist Clip rail fixing pins Support batten 10 11

7 Greenfloor controls Product compatibility Greenfloor controls are optimised for use with Greenfloor heating systems. The range of products includes wiring centres and components for individual room temperature control. Room thermostats Single room controls allow the temperature in each room to be set individually. The temperature is controlled by the thermostat in relation to variable factors such as solar heat gains, electrical devices and people. They are available as 230V wired controls or as wireless (RF) versions. Single room thermostats are available as wall mounted models. Wired programmable room thermostats are available as flush mounted models. Wiring centres Greenfloor wiring centres provide a quick, simple and safe means of wiring together room thermostats and actuators. The wired unit can be used with up to six 230V room thermostats, or programmable room thermostats. It can also operate up to 14 actuators. There is the facility to connect a time control which enables a night set-back 230V wiring centre mode and an interlock to stop the manifold circulating pump from operating. It also turns off the heat source (when all valves are closed). The wireless unit will receive signals from up to eight wireless thermostats and can be wired to a maximum of 16 actuators. The unit is supplied complete with a 7 day programmer that allows each zone to be programmed independently and works harmoniously with Worcester s wireless (RF) room thermostat. To stop the manifold circulating pump running and turning off the heat source, the unit incorporates an interlock. Actuators The 230V actuators are supplied by the Greenfloor wiring centres and control the water flow through each zone, according to the room thermostat s demand signal. They consume as little energy as just 2 Watts. Control Wired 230V option Wireless (RF) option Room thermostat Programmable room thermostat Wiring centre Actuator Yes Yes Yes Yes Yes No Yes Yes Greenfloor heating is designed to work with all Greenstar gas and oil-fired boilers and appropriate renewable technologies. Gas-fired boilers Regular Greenstar Ri series Greenstar CDi Regular series Greenstar FS CDi series System Greenstar i System series Greenstar 30CDi System Combi Greenstar i Junior series Greenstar Si Series Greenstar CDi series Greenstar Highflow CDi series Oil-fired boilers Regular Greenstar Danesmoor WM series Greenstar Camray series Greenstar Camray Utility series Greenstar Utility series Greenstar Camray External series System Greenstar Camray System series Greenstar Camray Utility System series Greenstar Camray External System series Combi Greenstar Heatslave series Greenstar Heatslave External series Boilers September 2011 Renewable technology Ground source heat pumps Greenstore System Ground Source Heat Pump series Greenstore Combination Ground Source Heat Pump series Air to water heat pumps Greensource Air to Water Heat Pump series 12 13

8 Installation requirements Pipe fixing methods Before a suitable Greenfloor pipe fixing method can be selected, consideration must be given to the following factors: The desired finished floor level and the available depth for installation The heat output required from the floor to accommodate the heat loss of the room and building The type of floor that Greenfloor will be installed within The desired floor finish. Wet screed floors Screed Greenfloor pipe positioning panels and Greenfloor staple panels are designed for use with either a standard sand and cement screed or a pumped liquid screed. Typically a 75mm screed depth is used. Greenfloor pipe positioning panels Greenfloor pipe positioning panels offer flexibility in achieving a balance of the finished floor level against the available installation depth. The panels are available with either 30mm or 11mm of polystyrene insulation. Alternatively an option with no insulation provides the ease and convenience of the panel fixing method and relies on the floor grade insulation installed on site. Greenfloor pipe positioning panels offer a number of advantages over other pipe fixing methods, while allowing an experienced installer a one man installation. Working with a 200m coil, Greenfloor PE-Xc system pipe can simply be walked into the pre-formed castellated sections of the panel. Greenfloor pipe positioning panel installations are also much easier to adjust should last minute changes be required to the layout of the installation. There are no clips to release, no damage to the panels and the pipe can easily be relaid to the revised requirements. Greenfloor pipe positioning panels deliver a highly professional finish to the installation procedure, prior to pressure testing and the screed being laid. Greenfloor staple panels Greenfloor staple panels are made of polystyrene insulation and are coated with a fully bonded, tear and waterproof woven fabric. This has a number of advantages, particularly in avoiding the situation with floor grade insulation where the staples can pull out. The Greenfloor staple panel also provides an installation grid at 50mm intervals for easy spacing of the Greenfloor PE-Xc system pipe. This is applied directly to the staple panel using staples and a stapler available from Worcester. Greenfloor staple panels are available in a choice of two installation thicknesses, 30mm and 35mm. It is recommended to fix the Greenfloor PE-Xc system pipe with Greenfloor staples every 300mm. More staples may be necessary on bends. The pipe spacing will be specified as part of the package of information supplied by the Worcester Design Service. Once the Greenfloor PE-Xc system pipe is installed, pressure testing must be carried out prior to the screed being laid. Greenfloor staples & Greenfloor clip rail Both of these products offer an alternative method of installing Greenfloor. A particularly low installation cost can be achieved by simply fixing the Greenfloor PE-Xc system pipe to the floor grade insulation installed on site. Greenfloor staples, installed using the Greenfloor stapler or Greenfloor clip rail, or a combination of the two, provides a robust fixing method prior to the screed being laid. We recommend fixing the Greenfloor PE-Xc system pipe with Greenfloor staples every 300mm, while more staples may be necessary on bends. Greenfloor clip rails should be fixed to the floor grade insulation using the self adhesive backing. This should be done prior to Greenfloor rail fixing pins being pushed into the insulation through the clip rail. This will provide a robust and secure fixing. Greenfloor clip rails should be fixed at no more than 1,000mm spacing between clip rails and no more than 500mm spacing from wall edges. They should be installed at 90 to the coldest external wall. Dry screed floors Greenfloor dry construction panels offer an alternative to the traditional approach of installing Greenfloor PE-Xc system pipe within 75mm of wet screed. The dry construction panel system is designed to be installed directly over an existing floor surface; this may be designed as part of a new construction or a retrofit at a later date. Greenfloor dry construction panels can also offer a solution where an existing floor is not able to withstand the weight or loading of a traditional wet screed, for example on timber suspended floors. The dry construction panels are laid over the existing floor surface and feature an interlock system to ensure secure installation of each panel to the next. Once the installation of the dry construction panels is complete, Greenfloor heat conducting plates are installed. The Greenfloor heat conducting plates allow the heat from the PE-Xc system pipe to radiate over a wider area to provide an even heat output. They are available in both straight and curved sections. The curved sections allow for a 180 bend at the edge of the installation area prior to installing the next straight section. On completion of the installation of the Greenfloor dry construction panels and heat conducting plates, the Greenfloor PE-Xc 14mm system pipe can be installed. Once the system pipe is installed, the Greenfloor dry screed system foil is placed over the whole area. This provides an intermediate layer to minimise the risk of movement or expansion noise against the finished floor surface. For pressure testing directions see page 17. Timber suspended floors Greenfloor offers a simple and effective solution for timber suspended floors which is particularly suitable for retrofit installations. Timber battens are fixed to run the length of the joists to provide a platform upon which the floor grade insulation can be installed. Greenfloor staples or clip rails can then be used to secure the Greenfloor PE-Xc pipe. Installation centres can be as close as 100mm to ensure maximum heat output is available for a comfortable, efficient and effective heating system. This style of installation is only recommended for use in timber suspended floors at 1st floor level and above. Ground floor installations should, wherever practical, employ a wet screed installation. This allows for maximum efficiency and avoids the risk of the ventilated area below drawing heat away from the floor surface. In all cases, the installer must plan for maximising thermal insulation and minimising drafts. Greenfloor timber suspended floor installations must successfully pass the same test criteria as a Greenfloor dry screed floor installation. For pressure testing directions see page 17. Clip rail staple Clip rail Pipe staple Support batten boards Joist underlay Greenfloor PE-Xc pipe Floor grade insulation After applying the Greenfloor PE-Xc system pipe, pressure 14 tests must be completed prior to the screed being laid. 15

9 Installation depths General requirements Below are the required depths for your chosen floor fixing method in addition to the allowance for insulation in accordance with the current Building Regulations (excluding final floor finish). Greenfloor dry construction panel system Screed type Dry Dry construction panel 0.2mm system foil 0.5mm heat conducting plate 25mm dry construction panel 25.7mm in total Greenfloor pipe positioning panel system Screed type Wet Screed type Wet Pipe positioning panel 30mm 75mm screed 30mm pipe positioning panel 105mm in total Pipe positioning panel 11mm 75mm screed 11mm pipe positioning panel 86mm in total Heat conducting plate Timber suspended floor or concrete base Pipe positioning panel Dry screed system foil Screed underlay Dry construction panel underlay Greenfloor PE-Xc pipe Greenfloor PE-Xc pipe Edging insulation strip Insulation to Building Regulations requirements In all instances, all floors must be insulated to the latest Building Regulations requirements. The thermal resistance of the pipe positioning, staple or dry construction panels may be calculated as part of the building s insulation programme or seen as an extra over the minimum compliance standard already planned. Pressure testing Once the PE-Xc system pipe is installed and connected to the Greenfloor stainless steel manifold, the installation must be pressure tested using the following procedure. Ensure the Greenfloor installation is isolated from the heat source using the valves between the pump and mixing station and the stainless steel manifold. Flush and fill each loop individually using a mains cold water supply by ensuring only the manual isolating valve and flow meter, for the current loop, are open when being flushed. Laying wet screed The screed should be laid as soon as possible after successful pressure testing of the Greenfloor installation. This should be supplied and installed in accordance with British Standards and the flooring manufacturer s instructions. As wet screed cures, it releases heat. As a result a slight increase in pressure may be observed. Once laid, all screeds require a period of time to cure. Curing periods are typically 21 days, but British Standards and the manufacturer s instructions must be followed. For the first 3-4 days the screed must not be walked on. Any pressure could introduce a weak spot to the screed and the potential for cracking in the future. Screed type Pipe positioning panel Light 75mm screed Wet 0mm pipe positioning panel 75mm in total Greenfloor staple panel system Screed type Staple panel 30mm 75mm screed Wet 30mm staple panel 105mm in total Sub floor Clip rail Pipe staple Concrete base Clip rail staple Screed underlay Insulation Greenfloor PE-Xc pipe Edging insulation strip Once all loops are flushed of air and filled, connect a suitable pressurisation pump to one of the fill and drain points on the manifold. Open each of the loops fully using the manual isolating valves and flow meters. Increase the pressure using the pump to 6 bar. An initial decrease can be expected as the Greenfloor PE-Xc system pipe expands. Following this decrease the pressure should be adjusted back to 6 bar. No other decrease should be seen. This test pressure must be successfully After the initial period has passed the screed can be walked on. The screed must then be covered with both a polythene barrier to maintain moisture levels and a protective plywood layer to prevent damage. At all times the screed supplier s instructions must be followed. At the end of the curing period, the system pressure should be adjusted to the normal working pressure of 1.5 bar by draining off via the fill and drain point. Screed type Wet Staple panel 35mm 75mm screed 35mm staple panel 110mm in total Sub floor Concrete base Insulation Edging insulation strip witnessed for at least 1 hour. After successful completion of the pressure test at 6 bar, the wet screed or floor finish can be laid. The pressure test should be maintained throughout the laying of the screed or floor finish. This protects the system pipe from The isolating valves between the pump and mixing station and the stainless steel manifold can then be opened to connect the heat source circuit with the Greenfloor installation. The heat source can then be turned on to aid the drying process. deformation and allows any damage incurred to be Pipe staple Greenfloor PE-Xc pipe immediately noticed. The temperature in the Greenfloor installation should be limited to 25 C for 3 days, then increased for a further Greenfloor staple and clip rail systems Timber suspended floor application shown. Clip rail staple Clip rail boards underlay 4 days to approximately 40 C. 16 Support batten Joist Floor grade insulation 17

10 Components Greenfloor PE-Xc pipe and manifolds It is suggested the screed is left to thoroughly dry for a further 7 day period. However this may be reduced so long as the installer of the finished floor is satisfied that any remaining moisture levels are within the specification of the finished floor product. The Greenfloor installation should be switched off and the screed allowed to cool for 3 days before installation of the finished floor product commences. Accommodating expansion All installations must be provided around the perimeter with a means of accommodating the expansion of the screed or the dry construction components. This takes the form of the Greenfloor edging insulation strip. Wet screed expansion Large areas of screed floor (over 40m 2 ) may also require regular Greenfloor expansion joint sections to physically separate the screed. These are self adhesive and fix easily to the floor fixing method. If Greenfloor pipe positioning panels are being used, a Greenfloor rounded section should be installed to provide a level platform upon which to install the expansion joint section. Wherever a screed expansion joint is added, the Greenfloor PE-Xc system pipe should be protected by a Greenfloor expansion protection tube to a distance of 300mm in each direction. Further information on wet and dry screed expansion can be found in the British Standards and Building Regulations as well as from the screed suppliers. Floor finishes for dry screed installations The finished floor must be installed immediately after pressure testing is complete to protect the installation. Laminate floor finishes with interlocking joints must be a minimum of 7mm thick. Plywood or chipboard floor finishes can be used but should be a minimum of 15mm thick with glued tongue and groove edges. Alternatives to plywood or chipboard fi nishes offering a lower resistance to heat output are also available. Further information can be found at your local builder s merchants. Preparing for commissioning Before the Greenfloor installation is operated the system pressure must be reduced to normal working pressure of 1.5 bar by draining off via the fill and drain point. The isolating valves between the pump and mixing station and the stainless steel manifold can then be opened to connect the heat source circuit with the Greenfloor installation. Greenfloor PE-Xc system pipe Greenfloor PE-Xc system pipe is available in two different diameters and two different lengths. There is a choice of 14mm dia. and 16mm dia. pipe, each with a 2mm side wall. The selection of the diameter depends on each particular installation and will be specified as part of the package of information provided by the Worcester Design Service. This is dependent upon factors such as total pipe length and pressure loss throughout the installation. Domestic installers will find the 200m long coils the most practical and easiest to work with. If installing regularly, for example on construction sites, it may be more practical to specify the larger coils which are available 14mm dia. as a 750m coil or 16mm dia. as a 650m coil. These much larger coils will reduce the amount of off-cuts. The coil is best handled when using a pipe reel and stand which are available from Worcester, and enables the pipe to be supported and easily uncoiled. Greenfloor PE-Xc system pipe is guaranteed for a period of 25 years. Greenfloor stainless steel manifolds Greenfloor stainless steel manifolds are available in a range of sizes to accommodate applications from 2 to 16 zones. It is also possible to connect two manifolds together. For example if an extension to the Greenfloor installation is required, or to accommodate unforeseen circumstances at installation stage. Greenfloor stainless steel manifolds feature flow connections on the lower manifold section. Incorporated flow meters allow each zone to be accurately commissioned. The zone specifications and the optimum number of ports will be provided in the package of information provided by the Worcester Design Service. The outlets of the manifold are 3 / 4 " and easily connect with Greenfloor PE-Xc system pipe using 3 / 4 " to 14mm or 16mm adaptors, according to the diameter of the pipe specified. The upper manifold section contains the return connections, again using 3 / 4 " adaptor fittings, the Greenfloor PE-Xc system pipe can be easily connected. Each port on the return manifold includes a 30mm threaded connection which incorporates a manual isolating valve and is expected to be replaced with a 230V actuator. This enables full control over each zone using either a wired or wireless control platform and wiring centre. Each manifold section also features a fill and drain point with a sealing cap provided, an automatic air vent and 1" connections to the chosen Greenfloor pump and mixing station. Greenfloor manifold cabinets A Greenfloor manifold cabinet may be specified and selected to offer a neat and tidy finish to the installation. Available as either flush mounted, which can be recessed into a wall prior to final plastering taking place, or surface mounted, which fits directly to a finished wall surface. The number of ports required on the manifold depend 18 on a number of factors including: The number of rooms in the property The size of the rooms The heat loss of the room and building The heat output required from the floor Limiting any one pipe run to no more than 120m, from the manifold and back. 19

11 Components Greenfloor controls, pump and mixing stations Wireless Wired Pump and mixing station installed at manifold Fixed value flow temperature Wireless wiring centre FRS standard pump and mixing station 230V wiring centre FRS standard pump and mixing station Greenfloor offers a number of combinations of controls and Greenfloor pump and mixing stations to suit individual installation needs. Comprehensive wiring instructions are supplied with each bespoke installation design provided by the Worcester Design Service, in addition to those supplied with the product. These are available to download from our website at Greenfloor controls wireless (RF) The Greenfloor wireless wiring centre provides a very easy to install control system without the restrictions of running cables to each individual room thermostat. The Greenfloor wireless wiring centre features a 7 day programmer which enables each of the zones connected to be controlled completely independently. Within each zone a Greenfloor surface mounted wireless room thermostat is fitted and through a simple pairing process is set to control the appropriate 230V actuator outputs within the wiring centre. The wiring centre is capable of receiving signals from a maximum of 8 surface-mounted wireless room thermostats and is able to provide output to a maximum of 16 actuators. The wiring centre also provides two separate volt-free interlock relays, one to control the heat source and one to control the Greenfloor pump and mixing station s circulation pump. Pump and mixing station installed remote of manifold Weather compensated flow temperature Wireless wiring centre VRS 7 weather compensated pump and mixing station OR VRS 10 weather compensated pump and mixing station 230V wiring centre VRS 7 weather compensated pump and mixing station OR VRS 10 weather compensated pump and mixing station Wireless wiring centre KMS 15 remote pump and mixing station OR KMS 25 remote pump and mixing station 230V wiring centre KMS 15 remote pump and mixing station OR KMS 25 remote pump and mixing station In larger installations it is possible to use more than one wiring centre. The wiring centres are to be wired in harmony to control the heat source and the Greenfloor pump and mixing station s circulation pump. Greenfloor controls 230V wired The Greenfloor 230V wiring centre provides an easy to install control system where running cables to each individual room thermostat is not a barrier, for example in new build and major renovation installations. Clearly identified and spring loaded connections mean installing cables can be completed efficiently. The Greenfloor 230V wiring centre is capable of receiving inputs from a maximum of 6 230V room temperature devices and is able to provide output to a maximum of 14 actuators. The wiring centre also provides an interlock relay to control the heat source and the Greenfloor pump and mixing station s circulation pump. Greenfloor controls recessed 230V programmable room thermostat The Greenfloor recessed 230V programmable room thermostat features 3 factory set programmes, selectable and adjustable at time of commissioning and operates on a 7 day basis. This enables individual days to be programmed differently if necessary. The programmable room thermostat also provides a 230V output when a reduced temperature economy mode is entered. This instructs the Greenfloor wiring centre that all dependent zones should also enter reduced temperature economy mode. Practically, this means that typically a single programmable room thermostat can be used per floor. For example, when a surface mounted 230V room thermostat is being used in each room, offering individual temperature control, it works to the same time patterns as the lead programmable room thermostat. Greenfloor controls surface mounted 230V room thermostat The Greenfloor surface mounted room thermostat allows for temperature control within each zone and is able to accept the 230V economy mode signal from a programmable room thermostat. It is possible to use any combination of 230V room temperature devices so long as the installation complies with current Building Regulations. Further advice will be provided in the specification package supplied by the Worcester Design Service bespoke to each installation s needs. Greenfloor pump and mixing stations Greenfloor offers a number of pump and mixing stations to suit individual installation needs. The Greenfloor FRS standard and VRS pump and mixing stations are designed to be installed directly onto the Greenfloor stainless steel manifold. The Greenfloor FRS standard pump and mixing station can satisfy a maximum designed heat output of 8kW and features a fixed temperature control output. The Greenfloor VRS pump and mixing stations are available in two heat outputs. One to satisfy 7kW maximum output and the larger model to provide a 10kW maximum heat output. Both feature intelligent weather compensated flow temperature output. The Greenfloor KMS pump and mixing stations do not fit directly to the Greenfloor stainless steel manifold. Instead they offer installation flexibility by being installed in a remote location, such as near to the heat source or within a plant room. They can be installed in any position between the heat source and the Greenfloor stainless steel manifold. The Greenfloor KMS pump and mixing stations are able to offer the greatest heat outputs of any Greenfloor pump and mixing station. Available in two heat outputs, a 15kW and 25kW maximum heat output, both feature intelligent weather compensated flow temperature output. Regulations, standards and further advice Further information regarding the design, specification and installation best practice principles of underfloor heating can be found in, but is not limited to the following documents, standards and regulations. Documents The CIBSE underfloor heating design and installation guide (2004) The CIBSE domestic heating system design guide (2004) The BPEC warm water underfloor heating for mechanical services engineers design course, handbook The BPEC warm water underfloor heating for mechanical services engineers installation course, handbook. Building Regulations England & Wales Part L (Energy Efficiency) Part E (Sound) Republic of Ireland Part L (Conservation of fuel & energy) Part E (Sound) Northern Ireland Technical Booklet F (Conservation of fuel & energy) Technical Booklet G (Sound) Scotland Technical Standards Section 6 (Energy) Technical Standards Section 5 (Sound) British Standards Full British Standards can be found on our website at

12 Specification and Design Service Worcester offers a fully bespoke specification and system design service to support the Greenfloor underfloor heating product range. Specification To request a specification, simply copy and complete the specification request form opposite or go to and submit your drawings. You will then receive a complete specification and component list for your project. We aim to provide this within two working days. Design Should you require a full design service, we will require you to submit the design request form attached to your specification and provide proof of purchase of the Greenfloor items for that project prior to us carrying out the work. You will then receive pipe layout drawings, circuit lengths, pressure losses, flow rate settings for each circuit and a full materials specification. We aim to provide this within 10 working days. Tel: underfloor.heating@uk.bosch.com 22 23

13 Greenfloor heating series components and accessories PE-Xc Pipe 14x2 Coil 200m PE-Xc Pipe 14x2 Coil 750m PE-Xc Pipe 16x2 Coil 200m PE-Xc Pipe 16x2 Coil 650m Stainless steel manifold Screw connection 14mm 3 / 4 " (pack of 10) Screw connection 16mm 3 / 4 " (pack of 10) Double nipple 3/ 4 " 1 / 2 " (pack of 6) Pipe reel Pipe reel stand Double screw connection Ball valve set 1" way way way way way way way way way way way way way way way Double nipple 3/ 4 " 3 / 4 " (pack of 6) Pipe positioning panel light 1.3m 2 (10m 2 pack) Pipe positioning panel for doors/connections 30mm (5m 2 pack) Manifold cabinet 560mm Surface mounted Manifold cabinet 700mm Surface mounted Manifold cabinet 1,000mm Surface mounted Manifold cabinet 1,300mm Surface mounted Pipe positioning panel for doors/connections 11mm (5m 2 pack) Pipe positioning panel 30mm, 1.3m 2 (10m 2 pack) Pipe positioning panel 11mm, 1.3m 2 (10m 2 pack) Pipe positioning panel Rounded section joint seal 25m Manifold cabinet 560mm Flush mounted Manifold cabinet 700mm Flush mounted Manifold cabinet 1,000mm Flush mounted Manifold cabinet 1,300mm Flush mounted Pipe positioning panel cutting tool Staple panel Roll 30mm (12m 2 pack) Staple panel Roll 35mm (12m 2 pack) Stapler

14 Pipe staples (pack of 300) Dry construction panel (13.1m 2 pack) Heat conducting plate straight section (pack of 50) Heat conducting curved section (pack of 25) FRS connection set FRS standard pump & mixing station up to 8kW Pipe bend guide (pack of 50) Expansion joint section (14x1.8m pieces) Dry screed system foil (100m 2 ) 230V wiring centre Surface mounted 230V room thermostat Surface mounted wireless room thermostat Expansion joint protection 14mm (25m roll) Expansion joint protection 17mm (25m roll) Rail fixing pins (pack of 500) Clip rail (100x1m pieces) Recessed 230V programmable room thermostat Wiring centre for wireless controls 230V actuator RMS single room pump & mixing station Edging insulation strip ( 50m roll) KMS 15 remote pump & mixing station up to 15kW KMS 25 remote pump & mixing station up to 25kW VRS 7 weather compensated pump & mixing station up to 7kW VRS 10 weather compensated pump & mixing station up to 10kW

15 The very best training programmes from Worcester Worcester has always placed great emphasis on technical support and training for installers and service engineers. Advances in heating technology, including the increasing use of renewables, make the need for training greater than ever. To ensure the highest levels of competence and expertise in the installation of all Worcester products, the company runs intensive training courses for installers, commissioning engineers and operatives involved with servicing and fault finding. Mobile training To complement our training venues across the country, we can also bring training to you. We have mobile vehicles fully equipped with operational Greenstar gas-fired boilers, dry strip-down models and even a Greensource air to air heat pump, ensuring that quality training in a comfortable environment can be achieved on your doorstep! Worcester training courses One stop shop training We are here to provide you with training and assistance for all areas of your business, not just product training. Call us on to order a full training course brochure. Boiler training courses Greenstar CDi gas-fired condensing combi boilers Models covered Greenstar 27/30/37/42CDi Duration: 1 day Greenstar i Junior & Si gas-fired condensing combi boilers Models covered Greenstar 24/28i Junior and Greenstar 25/30Si Duration: 1 day Greenstar Highflow CDi & FS CDi regular floor standing gas-fired condensing combi and regular boilers Courses available Our training facilities offer a number of courses suitable for the installer and commissioning engineers, and more in-depth courses for the servicing and fault finding engineers. Training centres throughout the UK To enable us to meet the growing demand for training we have invested in additional facilities at the award-winning training academy at our Worcester headquarters. In addition to the original academy there is now a new 400m 2 unit, 25% of which is devoted to an open-plan domestic training area with life-size single-storey brick buildings. These feature working Greenskies solar thermal systems which enable installers to get up onto the roof of the building to get more realistic training. There are bays full of all Greenstar gas-fired appliances, so installers can really get to grips with the importance of system design. The additional space will also contain dedicated training areas for our renewable and future products. The training centre will also run certified CODNC01 and COCN1 courses. CODNC01 equips installers with the relevant qualifications for the changeover from domestic to commercial gas work. COCN1 allows existing commercial installers to renew their qualification. Further academies are located at West Thurrock in Essex, Bradford and Clay Cross in Derbyshire, all offering our full suite of courses. Please phone for more information about a course near you. Each course is run by specialist trainers and is superbly equipped to deliver a combination of classroom theory and practical hands-on experience that s second to none. If it's oil training you require, our 7.5 tonne mobile oil vehicle is available throughout the country for hands-on product training and OFTEC assessments. Distance learning/web based learning Worcester has produced a selection of Distance Learning CD ROMs/DVDs which are packed with information. Call for your copies, or visit for information on Web Based Learning. Get on course for a more profitable future now. Call now for more information Aberdeen Dundee Dunfermline Johnstone Durham Belfast Burnley Dublin Bradford Clay Cross Models covered Greenstar Highflow 440/550CDi and Greenstar FS 30/42CDi Regular Duration: 1 day Greenstar system & regular gas-fired condensing boilers Models covered Greenstar 12/15/18/24Ri, Greenstar 30/40CDi Regular, Greenstar FS 30/42CDi Regular, Greenstar 30CDi System and Greenstar 12/15/18/24i System Greenstar Danesmoor, Heatslave & Camray high efficiency condensing oil-fired boilers pre-oftec training Duration: 1 day Models covered Greenstar Danesmoor series, Greenstar Heatslave series and Greenstar Camray series Duration: 1 day Greenstar controls Models covered MT10, MT10RF, DT20RF, DT20, DT10RF, TD200, RT10, FR10, FR110, FW100 and ISM1 Duration: 1 day Renewable training courses Greenskies solar hot water system Covering Installation, commissioning and servicing Duration: 2 days Greenskies advanced solar Covering Worcester solar control range and pump stations Duration: 1 days Greenstore ground source heat pumps Covering Installation, commissioning and system design Duration: 2 days Greensource heat pumps air to water Covering Installation, commissioning and system design Duration: 2 days Greensource heat pumps air to air Covering Installation, commissioning and system design Duration: 1 day Greenfloor heating Covering Installation, commissioning and servicing Duration: 1 day Greenstream MVHR Covering Installation, commissioning and system design Duration: 1 day College-linked Learning As well as offering training at our own centres, Worcester has established close partnerships with many colleges around the UK, equipping them with our latest products. Call us on to find out when we will be running the course of your choice at a college in your area. Camborne Worcester Tredegar West Thurrock Salisbury 28 29

16 Industry focused training courses BPEC warm water underfloor heating installation Covering BPEC ventilation Basic principles & advantages of underfloor heating, floor systems and finishes, operation, installation, testing and post installation activities Duration: 2 days Covering Installation, commissioning, inspection and testing Duration: 2 days Hot water systems & safety A complete after-sales service As part of the worldwide Bosch Group, Worcester strives to maintain the highest possible standards of after-sales care. All the technical advice you need Covering Chemical water treatment All G3 Regulations for the installation, servicing and commissioning of unvented cylinders. This course is certified by Logic Certification. Duration: 1 day Covering Water treatment of domestic heating systems in accordance with BS 7593: 2006 Duration: 1 day Construction skills F-Gas training/assessment certification Covering Qualifies for Construction Skills Certification & Registration (valid for 5 years) and Voluntary ACRIB Registration OFTEC training and assessment OFTEC 101 Duration: 4 days Domestic ACS training and assessment Initial CCN1 + 4 appliances + CPA1 Covering Designed for candidates whose qualifications expired more than 12 months ago Duration: 5 day Reassessment CCN1 + 4 appliances + CPA1 Covering Re-assessment for candidates whose CCN1 qualification expires in less than 12 months Duration: 4 days Covering Domestic/light commercial pressure jet commissioning and servicing Duration: 3 days OFTEC 105e Covering Domestic/light commercial pressure jet boiler installation Duration: 1 day assessment OFTEC 101 & 105e Covering Domestic/light commercial pressure jet installation, commissioning and servicing Duration: 3 days OFTEC 600a Covering Oil tank installation and associated controls Duration: 1 day assessment OFTEC 101/105e/600e Covering Mobile OFTEC Domestic/light commercial pressure jet boiler installation, commissioning, servicing and oil tank installation and associated controls All above covered throughout the country on the mobile training vehicle as well as in all our centres Duration: 4 days Please note to attend OFTEC courses you must have a minimum of 12 months experience installing/servicing oil boilers. For inexperienced candidates, our Greenstar Danesmoor, Heatslave and Camray course offers pre-oftec training. For experienced oil technicians training is not a pre-requisite for OFTEC assessment. In addition to the no-nonsense parts and labour guarantee applicable to all Worcester products, you and your customers have the assurance that every Worcester product is manufactured to both the appropriate British and European standards. Worcester Contact Centre Should you require support, our fully trained Contact Centre staff, based at our head office in Worcester, are ready to take your calls. Whatever your query our contact centre operators along with our nationwide team of engineers are ready to help you. Boiler Protection Options Worcester offers boiler protection including service and maintenance contracts. Please call the Worcester Contact Centre for further details. If you do not offer annual service and maintenance contracts please refer your customers to the Worcester Contact Centre: Tel: Fax: Opening Times Monday Friday: 7.00am 8.00pm Saturday: 8.00am 5.00pm Sunday: 9.00am 12 noon Spares Genuine replacement parts for all supported Worcester products are readily available from stock, on a next day delivery basis. For more information please call your local stockist. You can find a spares stockist on our website. Customer Technical Support The Worcester Technical Helpline is a dedicated phone line committed to providing a comprehensive service to complement the brand name and quality of our products. Our experienced team of technical experts provides answers to queries of a technical nature across the entire Worcester range. Worcester also has a pre-sales team, who provide assistance in selecting a heating system to suit a particular application, along with full guidance on installation. For more information please contact the Technical Helpline or alternatively visit our website where literature can be downloaded at Technical Tel: Fax: Opening Times Monday Friday: 7.00am 8.00pm Saturday: 8.30am 4.00pm 30 31