Installation and Maintenance Instructions Radiance Thermal Interface Units (TIU) RAPID - RTIU702XXX Twin plate exchanger unit to generate instantaneous DHW with indirect heating connections. Designed and manufactured in the UK Conforms to Building Regulations Part L (2010)
Contents Reliance Worldwide Corporation (UK) Ltd 3 Dos and Don ts 4 Safety 5 Abbreviations 6 General Information 6 Working Parameters and Specifications 7 Dimensions 8 Internal System Components Schematic 9 Diagram 10 Operation 11 Domestic Hot Water Demand 11 Space Heating Demand 11 Installation 12 Unpacking the unit 12 Installation - No First Fix Rail and No Stand 13 Off Frame Fitting Location 13 Fitting Template 13 Wall Mounting 13 Connecting the Ball Valves 13 Fitting Template (Example) 14 Installation - with First Fix Rail and no Stand 15 Off Frame Mechanical Fixing 15 Installing the First Fix Rail 16 Fitting Template 17 Wall Mounting 17 Connecting the Ball Valves 17 Installation - Stand Off Frame with (Optional) 18 First Fix Rail Mechanical Fixing 18 Installing the First Fix Rail for Stand 19 Off Stand Off Frame Assembly 19 Fixing the Stand Off Frame to the 20 FFR for Stand Off Frame Fixing the Stand Off Frame Directly 20 onto the wall Mounting the TIU to the Stand Off 20 Frame Connecting the Ball Valves 21 Replacing the Cover 22 Hydraulic Connections 23 SharkBite Metal Push-Fit Connectors 24 Electrical Installation 25 Junction Box 26 Circuit Diagram 26 Commissioning 27 Flushing the Network 27 Filling the TIU 27 Filling the Primary Circuit 27 FIlling the Mains Water Circuit 27 FIlling the Secondry Circuit 27 Differential Pressure Control Valve 28 Diverter Valve 29 Disassembly 29 Assembly 30 Thermostatic By-pass Valve & 31 Thermostatic Heating Control Valve Zone Valve 31 Thermostatic Mixing Valve 32 Servicing the TMV 32 Pump 33 Heat Meter 33 Error Codes 33 Screen Functions 34 Maintenance 35 Strainers 35 Troubleshooting 36 Fault Finding Flowchart 37 Symptoms and Actions 38 Spares and Accessories 39 Commissioning Check Sheet 40 Servicing and Service Records 41
Reliance Worldwide Corporation (UK) Ltd Reliance Worldwide Corporation (UK) Ltd is part of the Australian based group of companies collectively known as Reliance Worldwide Corporation with two brands represented in the UK: Reliance Water Controls and SharkBite. Reliance Worldwide Corporation have offices and manufacturing plants throughout the world providing a wealth of knowledge and expertise which is delivered throughout our entire product range. Reliance Worldwide Corporation (UK) Ltd have a long history in supplying the sanitary plumbing market and hot water system manufacturers and are at the forefront of developing thermostatic technology in the UK. As specialists in the design, manufacturing and technical support for pressure, temperature and flow control, we also played a key role in the development of unvented hot water systems in the UK. Our Reliance Water Controls range offers a comprehensive selection of thermostatic mixing valves, taps, showers, pressure reducing valves, backflow prevention products, timeflow controls and other plumbing and heating system products. Our reputation is built upon over of 30 years experience both as a direct supplier and as an OEM manufacturer to many of the UK plumbing and heating industry s leading brands for safety valves in G3 unvented systems and Underfloor Heating (UFH) Controls. We are certified manufacturers to BS EN 9001 and 14001 and also have an in house UKAS accredited test laboratory. We are also members of multiple industry and trade associations, which allows us to remain at the forefront of new regulations and changes within the industry, which we reflect in our ongoing product development and innovations. 3
Dos and Don ts Do Not: Over tighten the union connections as this can split the fibre washer. Remove the clips at the top of the unit holding the rail connectors in place. Get any solder, flux or dirt inside the unit or into the ball valves or connections. Flush and/or pressure test the network while the unit is connected to it. Flush the primary or secondary side through the unit. Use flux or chemicals which could harm parts made of stainless steel, brass, copper or fibre washers Do: Always use two tools to block the adjacent part when tightening a union nut connection so that other connections are not affected and accidentally loosened. Ensure all connections are leak free after installation 4
Safety Please read this instruction and maintenance guide carefully before begining the installation. Reliance Worldwide Corporation (UK) Ltd (RWC UK) accepts no liability for any damage or injury caused by not observing the instructions in this guide. Failure to comply with these instructions will result in the warranty becoming null and void. Keep this manual in a safe place for future reference. If you are in any doubt, please contact the RWC UK technical department on 01386 712400 or email technical@rwc.com quoting the part number (RTIU702XXX) which is located on the backplate of the TIU. The Radiance TIU comes with a standard warranty of 2 years for material and manufacturing defects from date of delivery. Hot Water Temperatures in the Radiance TIU can reach up to 95 C and can cause severe burns. Hot Surfaces The Radiance TIU can get very hot when operating. Take care when working around the Radiance TIU. Whilst it is operating please avoid touching the pipework and all metal parts, which could be hot and could result in burns. Electricity Before conducting work on the Radiance TIU make sure that it is electrically isolated, either by unplugging it from the mains supply or turning off the isolation switch. Failure to do so could result in electric shock. Electrical installation and servicing must be carried out by a qualified electrician and to the current applicable standards. Lifting a Radiance TIU The Radiance TIU weighs up to 45 Kg, always use 2 people to lift the unit. Before lifting make sure that any obstructions are removed. When lifting ensure a stable position is adopted to maintain balance and grip. At the start of the lift, slight bending of the back, hips and knees is preferable to fully flexing the back (stooping) or fully flexing the hips and knees (squatting). Servicing The Radiance TIU should be serviced at least annualy by a qualified technician. The servicing record sheet and the recommended maintenance for the Radiance TIU can be on page 41 of this Installation & Maintenance (I&M) guide. Potable Water All the TIU compounds, joints and seals that are in contact with potable water are WRAS approved. Disposal Please recycle the cardboard packaging. The Radiance TIU itself cannot be disposed of with household waste. The Radiance TIU needs to be disassembled and the individual components disposed of according to local regulations. 5
Abbreviations Below are a list of abbreviations that are used in this booklet: BCW Boosted Cold Water PHE Plate Heat Exchanger DHW Domestic Hot Water TBPV Thermostatic Bypass Valve DPCV Differential Pressure Control Valve THCV Thermostatic Heating Control Valve FBP Flushing Bypass TIU Thermal Interface Unit FFR First Fix Rail TRV Thermostatic Radiator Valve MCB Miniature Circuit Breaker UFH Under Floor Heating General Information Radiance Thermal Interface Units are part of a heating network which is supplied from a central boiler room. They are designed to provide space heating and domestic hot water to an residence. The TIU is generally located within the apartment and connects to a heat network and boosted cold water on the primary (supply) side and to the space heating and DHW outlets on the secondary side. Product Description - Rapid (RTIU702XXX) The Rapid family of Radiance TIUs are designed to supply indirect heating (hydraulically separated between the primary and secondary circuit by a plate heat exchanger) and instantaneous DHW. The hot water is heated at the time of use in a plate heat exchanger and not stored in a cylinder. Intended Usage Radiance TIUs must be installed by a competent person to ensure they perform as designed. All pipe connections and electrical connections must to be completed by trained professionals according to and conform to IEE regulations. Technical Description The Rapid family of TIUs are twin-plate (2 PHE) units designed to provide space heating and DHW. The unit connects the primary heat network, the secondary space heating (radiators or UFH) and to the BCW supply to produce DHW. Heating Controls There is no hydraulic by-pass included on the secondary side of the Rapid TIU. This means that the external controls need to switch off the call for heat when all valves of the heating system are closed and there is no demand. This will prevent the circulation pump running against a closed system and consequently overheating. This issue is normally overcome by fitting the heating controls in the coldest room (for example the hall) where the radiator should not fitted with a TRV and all valves at the radiator are fully open. The room thermostat should not be installed in direct sunlight. The hall will now be temperature controlled by the room stat/timer and the radiator in the hall also performs a hydraulic bypass to the unit. All other radiators in the system should be fitted with TRVs. 6
Working Parameters and Specifications Rapid Specification: Indirect heating and instantaneous domestic hot water unit. Weight 45 (approx.) Kg Pressure Rating Primary (max.) Secondary (max.) Cold water mains (min.) Cold water mains (max.) 10 3 2 4 bar bar bar bar Temperature Differential Pressure Primary (min.) Primary (max.) Domestic hot water Primary (max.) Primary (min.) 65 95 30-60 2.5 0.5 Differential Pressure Factory set 0.3 bar Control Valve Heat Transfer Capacity *Higher kw available Heating circuit DHW circuit 15 42 (Std.)* kw kw DHW Flow Rate Temp. rise from 10-50 15 l/min. Circulation Pump Branded A rated UK Pump head 6m Standard body 130mm(L) with 1½" connections External Connections Primary flow Primary return Secondary flow Secondary return Boosted cold water Domestic hot water 22mm SharkBite push-fit connections 22mm SharkBite push-fit connections 22mm SharkBite push-fit connections 22mm SharkBite push-fit connections 22mm SharkBite push-fit connections 22mm SharkBite push-fit connections or or or or or or ¾ FBSP ¾ FBSP ¾ FBSP ¾ FBSP ¾ FBSP ¾ FBSP Thermostatic Bypass Adjustable 40-70 C C C C bar bar 7
813 Dimensions 504 250 All dimensions in mm unless otherwise stated 8
Rapid Internal System Components (Schematic) Key 1. Ball valve connections 1A - Primary flow (PF) 1B - Primary return (PR) 1C - Secondary flow (SF) 1D - Secondary return (SR) 1E - Domestic hot water (DHW) 1F - Boosted cold water (BCW) 2. Strainers 3. Diverter valve for DHW 4. Plate heat exchanger - heating 5. Circulation pump heating system 6. Heat meter (optional) 7. Differential pressure control valve 8. Thermostatic by-pass valve (optional) 9. Primary zone valve 10. Patented spring loaded, maintenance free expansion vessel 11. Overpressure relief valve with pressure gauge 12. Plate heat exchanger - DHW 13.Thermostatic mixing valve DHW (optional) 14. Flow sensor DHW 15. Thermostatic heating control valve (optional) 9
Rapid Internal System Components (Diagram) 1A 1B 1F 1E 1C 1D 6 2 Backplate 2 5 First Fix Rail (FFR) 7 14 8 13 11 15 9 16 12 3 10 4 1G Key Ball valve connections 1A - Primary flow (PF) 1B - Primary return (PR) 1C - Secondary flow (SF) 1D - Secondary return (SR) 1E - Domestic hot water (DHW) 1F - Boosted cold water (BCW) Bottom connections 1G - Overpressure relief connection 2. Strainers 3. Diverter valve for DHW 4. Plate heat exchanger - heating 5. Circulation pump heating system 6. Heat meter (optional) 7. Differential pressure control valve 8. Thermostatic by-pass valve (optional) 9. Primary zone valve 10. Patented spring loaded, maintenance free expansion vessel 11. Overpressure relief valve with pressure gauge 12. Plate heat exchanger - DHW 13.Thermostatic mixing valve DHW (optional) 14. Flow sensor DHW 15. Thermostatic heating control valve (optional) 16. Wiring center 10
Operation The Rapid TIU can either supply heating or domestic hot water but not both simultaneously. The DHW has an inbuilt priority, the heating will be switched off when DHW is drawn, but as DHW demands are very short, no impact on the heating performance will be experienced. DHW Demand 1F When a hot tap is opened potable cold water will flow into the unit at (1F) and through the flow switch (14). The flow switch activates the diverter valve (3) which will divert the primary flow into the PHE for the DHW (12). The potable cold water will be heated in the PHE and exitthe PHE as DHW. The optional TMV (13) will blend the DHW to a pre-set temperature. Flow Switch (14) Plate Heat Exchanger (12) TMV (13) Diverter Valve (3) Space Heating Demand The space heating is controlled by external controls (timer, programmable room thermostat). When a demand for heat is generated, the call for heat wired into the TIU will activate the primary zone valve (9). This allows the primary hot water to flow through the heat exchanger and simultaneously, start the circulation pump (5) which will pump the secondary circuit through the radiators. The secondary water will be heated in the PHE by the primary hot water flow. The flow rate on the primary side is controlled by the DPCV (7), the primary zone valve (9) and if specified the optional thermostatic heating control valve. Please see the Electrical Connections chapter for the wiring diagram. DPCV (7) TH CV(15) Circulation Pump (5) Zone Valve (9) 11
TOP OF BACK PLATE PRIMARY PRIMARY FLOW RETURN COLD WATER WATER OUT FLOW 479mm TOP OF BACK PLATE Installation Radiance TIUs weigh up to 45kg. Always use 2 people to lift the unit. The boxes are clearly marked with arrows indicating the top of the box. They also have 2 hand slots at both ends to aid handling. Unpacking FIXING POINT COLD WATER MAINS DOMESTIC HOT Place the box on a strong, level surface and open the top cover with a box cutter. FIXING POINT 1) Remove this fitting template from the box and keep it for the installation. 2) Remove the white steel cover of the TIU by holding the cover by the openings in the centre of either end. 3) Lift the TIU out of the box. When lifting the TIU make sure that you hold it from the corners, holding the backplate or the expansion vessel. Do not hold the TIU from the pipework or components as this can loosen or damage the pipework and connections. 1) Select a suitable location which will securely support the weight of the unit (45kg). 2) The fitting template can simply be hung on the First Fix Rail (FFR) if this option has been fitted. 3) Otherwise, the fitting template needs to be temporarily held vertically to the wall. 4) Drill through the 4 holes which are marked Fixing Points or use the dimensions printed on the template. 479mm 700mm 5) Remove the template and fit suitable wall fixings before securing the TIU to the wall. 6) The pipe connections at the top are marked with their location, flow directions and type of connection. FIXING POINT 700mm Thermal Interface Unit (TIU) SECONDARY SECONDARY RETURN FIXING POINT On top of the TIU is a cardboard template to protect the cover of the unit, which is also a fitting template. Remove the fitting template from the box and keep it safe for the installation, as it contains all relevant information to mount the unit to the wall. A Remove the white steel cover of the TIU by lifting it out of the box. The cover has hand slots in the centre of both ends where it can be lifted (fig. 1). Fig. 1 Hand slot When lifting the TIU out of the box make sure that you lift from the corners, holding the backplate or the expansion vessel. Place the TIU on a strong, level surface. Do not lift the TIU with the pipework or connected valves, as shown below, as this can loosen or damage the pipework and connections. 12
TIU Installation - No First Fix Rail and No Stand Off Frame Fitting Location Select a location (usually the utility cupboard) where the unit can be fitted securely to the wall. The unit is heavy and needs a sturdy wall and appropriate fixings to support its weight. All pipe connections, with exception of the over pressure relief pipe, are connected at the top. All top connections at the top are terminated in 22mm SharkBite metal push fit ball valves or ¾ FBSP connections. Fitting Template Hold the cardboard fitting template level at the intended location of the TIU (fig. 1). The fitting template should be used to mark where the pilot holes are to be drilled through the 4 points marked Fixing Point (fig. 2). The wall is now ready to have the TIU mounted to it. TOP OF BACK PLATE PRIMARY FLOW FIXING POINT fig. 1 PRIMARY RETURN COLD WATER MAINS 65m (CENTRE TO DOMESTIC HOT WATER 479mm Thermal Interface If the fitting template is not available use the dimensions given on page 14 to mark the location of the fixing points fig. 3 fig. 4 Wall Mounting 1. Insert rawl plugs into the drilled holes. 2. Partially insert the 4 screws with metal washers into the rawl plugs. 3. Hook the TIU over the 4 screws (fig. 3) and slide down so that the screw head is at the top of the slot (fig. 4). Note: Radiance TIUs are heavy and weigh up to 45kg. Always use 2 people to lift the units. 4. Tighten the screws with a screwdriver. The TIU is now wall mounted and ready to have the ball valves connected. Connecting the Ball Valves to the TIU 700mm Unpacking the cover by the openings in the sure that you hold it from the backplate or the expansion v 1) Remove this fitting template for fig. the 2installation. 2) Remove the white steel cove 3) Lift the TIU out of the box. W Do not hold the TIU from the pipew this can loosen or damage the pipe Fitting the T the weight of the unit (45kg). First Fix Rail (FFR) if this opt Fixing Points or use the dim before securing the TIU to th location, flow directions and t 1) Select a suitable location wh 2) The fitting template can simp 3) Otherwise, the fitting templat held vertically to the wall. 4) Drill through the 4 holes whic template. 5) Remove the template and fit 6) The pipe connections at the t The ball valves are supplied loose in a separate box and will have either SharkBite or ¾ FBSP connections. They connect to the TIU via a flat face fibre washer sealed union nut connection. To connect the ball valves to the TIU: 1. Remove the plastic cap from the ball valves, taking care as the cap contains a loose fibre washer inside. 2. Place a fibre washer in each ¾ FBSP connection. 3. Screw the nuts at the top of the TIU onto the ball valves, using the washer to form a seal. Tighten with a spanner. 4. Do not remove the rail clips. These keep the rail connectors in place and prevents the loosening of internal components. FIXING POINT www.rwc.co.uk/r For technical support ca Reliance Worldwide Corporation (UK) Ltd, Worces Rail clip 479mm The TIU is now ready for the pipework connections. 13
This drawing is representative of the fitting template and is not to scale TOP OF BACK PLATE PRIMARY FLOW PRIMARY RETURN COLD WATER MAINS DOMESTIC HOT WATER COLD WATER OUT SECONDARY FLOW TOP OF BACK PLATE SECONDARY RETURN FIXING POINT 479mm Thermal Interface Unit (TIU) FIXING POINT Unpacking the TIU 1) Remove this fitting template from the box and keep it for the installation. 2) Remove the white steel cover of the TIU by holding the cover by the openings in the centre of either end. 3) Lift the TIU out of the box. When lifting the TIU make sure that you hold it from the corners, holding the backplate or the expansion vessel. Do not hold the TIU from the pipework or components as this can loosen or damage the pipework and connections. 700mm Fitting the TIU 1) Select a suitable location which will securely support the weight of the unit (45kg). 2) The fitting template can simply be hung on the First Fix Rail (FFR) if this option has been fitted. 3) Otherwise, the fitting template needs to be temporarily held vertically to the wall. 4) Drill through the 4 holes which are marked Fixing Points or use the dimensions printed on the template. 5) Remove the template and fit suitable wall fixings before securing the TIU to the wall. 6) The pipe connections at the top are marked with their location, flow directions and type of connection. 700mm www.rwc.co.uk/radiance For technical support call 01386 712400 Reliance Worldwide Corporation (UK) Ltd, Worcester Road, Evesham, WR11 4RA FIXING POINT 479mm FIXING POINT 14
700 137 TIU Installation - with First Fix Rail and no Stand Off Frame The FFR is intended to be used as a first fix support. It is supplied with six SharkBite 22mm metal push fit connection ball valves as standard or ¾ FBSP connections are also available, as an alternative. This FFR permits the pipework to be pre-installed independent of the main TIU. The pipework can be flushed and pressure tested, before the TIU is installed and connected to the system. It is critical that the FFR is installed prior to the TIU. Mechanical Fixing The drawing below shows the back plate of a TIU mounted onto the optional FFR at the top. The FFR has 2 fixing points with a dimension of 326mm across centres. The back plate has 4 fixing points with a dimension of 479mm across the centre. Heavy duty screws and rawl plugs should be used, which are suitable for the wall type. The TIU is heavy and weighs up to 45 Kg. If unsuitable screws are used damage could be done to both the wall and the TIU. All fixing points are large enough to be used with screws up to 8mm in diameter. 77 326 Diagram shows backplate and first fix rail only for ease of understanding 479 All dimensions in mm unless otherwise stated 15
Installing the FFR Choose a suitable location (usually the utility cupboard) ensuring there is sufficient space to fix the TIU below where the TIU can be fitted securely to the wall. The TIU is heavy and needs a sturdy wall and appropriate fixings to support the weight. All pipe connections, apart from the overpressure relief pipe, are connected at the top. The box that the FFR is supplied in contains a template which assists the installation. To use the template: 1. Hold the cardboard fitting template level at the intended location of the TIU. 326mm TOP PRIMARY FLOW PRIMARY RETURN COLD WATER MAINS DOMESTIC HOT WATER COLD WATER OUT SECONDARY FLOW SECONDARY RETURN www.rwc.co.uk/radiance For technical support call 01386 712400 Reliance Worldwide Corporation (UK) Ltd, Worcester Road, Evesham, Worcestershire, WR11 4RA, UK. 2. The fitting template can be used to drill pilot holes directly through the red crosshairs or used to mark the required location of the holes. 3. Insert rawl plugs into the drilled holes. 4. Partially insert the 2 screws with metal washers into the rawl plugs and hook the FFR over them. 5. Tighten the screws with a screwdriver. 16
TOP OF BACK PLATE PRIMARY FLOW FIXING POINT TOP OF BACK PLATE PRIMARY COLD WATER DOMESTIC HOT COLD WATER SECONDARY SECONDARY RETURN MAINS WATER OUT FLOW RETURN FIXING POINT Reliance Worldwide Corporation (UK) Ltd, Worcester Road, Evesham, WR11 4RA FIXING POINT FIXING POINT TIU Fitting Template 700mm 479mm Thermal Interface Unit (TIU) Unpacking the TIU 1) Remove this fitting template from the box and keep it for the installation. 2) Remove the white steel cover of the TIU by holding the cover by the openings in the centre of either end. 3) Lift the TIU out of the box. When lifting the TIU make sure that you hold it from the corners, holding the backplate or the expansion vessel. Do not hold the TIU from the pipework or components as this can loosen or damage the pipework and connections. Fitting the TIU 1) Select a suitable location which will securely support the weight of the unit (45kg). 2) The fitting template can simply be hung on the First Fix Rail (FFR) if this option has been fitted. 3) Otherwise, the fitting template needs to be temporarily held vertically to the wall. 4) Drill through the 4 holes which are marked Fixing Points or use the dimensions printed on the template. 5) Remove the template and fit suitable wall fixings before securing the TIU to the wall. 6) The pipe connections at the top are marked with their location, flow directions and type of connection. www.rwc.co.uk/radiance For technical support call 01386 712400 479mm 700mm The TIU fitting template is shown on page 14 (not to scale) and is supplied with the TIU. The cardboard template should be hung directly onto the FFR. The two rectangular openings at the top of the template allow the template to be hung from the FFR (fig. 1). Once hung, the fitting template can be used to drill pilot holes directly through the 4 points marked Fixing Point. Remove the fitting template. The wall is now ready to have the TIU mounted to it. TOP OF BACK PLATE PRIMARY FLOW PRIMARY RETURN fig. 1 Wall Mounting 1. Insert rawl plugs into the drilled holes. 2. Partially insert the 4 screws with washers into the rawl plugs. 3. Hook the TIU over the 4 screws (fig. 2) and slide down so that the screw head is at the top of the slot (fig. 3). Note: Radiance TIUs are heavy and weigh up to 45kg. Always use 2 people to lift the units. 4. Tighten the screws with a screwdriver. The TIU is now wall mounted and ready to have the ball valves connected. fig. 2 fig. 3 Connecting the Ball Valves to the TIU The ball valves are supplied loose in a separate box and will have either SharkBite or ¾ FBSP connections. They connect to the TIU via a flat face fibre washer sealed union nut connection. To connect the ball valves to the TIU: 1. Remove the plastic cap from the ball valves, taking care as the cap contains a loose fibre washer inside. 2. Place a fibre washer in each ¾ FBSP connection. 3. Screw the nuts at the top of the TIU onto the ball valves, using the washer to form a seal. Tighten with a spanner. 4. Do not remove the rail clips. These keep the rail connectors in place and prevents the loosening of internal components. Rail clip The TIU is now ready for the pipework connections. 17
700 141 TIU Installation - Stand Off Frame with First Fix Rail The stand off frame enables the pipework to be routed from below the TIU and run behind the TIU by locating the TIU away from the wall by 40mm. If the stand off frame is to be used in conjunction with a FFR it must be used with the FFR for stand off frame only. It will not work with the normal FFR and the pipework will not align. The FFR for the stand off frame must be wall mounted first, as the stand off frame hooks onto, it to provide location. Mechanical Fixing The drawing below shows the back plate of a TIU, mounted to the stand off frame, and with the optional FFR. The FFR has 2 fixing points with a dimension of 454mm across the centre. The back plate has 4 fixing points with a dimension of 479mm and 700mm across the centres. Heavy duty screws and rawl plugs should be used, which are suitable for the wall type. The TIU is heavy and weighs up to 45 Kg. If unsuitable screws are used damage could be done to both the wall and the TIU. All fixing points are large enough to be used with screws up to 8mm in diameter. 12 454 Diagram shows backplate and first fix rail only for ease of understanding 479 All dimensions in mm unless otherwise stated 18
Installing the FFR Choose a suitable location (usually the utility cupboard) ensuring there is sufficient space to fit the TIU below where the TIU can be fitted securely to the wall. The TIU is heavy and needs a sturdy wall and appropriate fixings to support the weight. All pipe connections, apart from the overpressure relief pipe, are connected at the top. The box that the FFR for the stand off frame is supplied in contains a template which assists the installation. To use the template: 1. Hold the cardboard fitting template level at the intended location of the TIU. 454mm PRIMARY FLOW PRIMARY RETURN COLD WATER MAINS DOMESTIC HOT WATER COLD WATER OUT SECONDARY FLOW SECONDARY RETURN 2. The fitting template can be used to drill pilot holes directly through the red crosshairs or used to mark the required location of the holes. 3. After drilling the holes in the correct location, insert appropriate fittings into the wall. 4. Using suitable screws and washers, insert them into the rawl plugs and screw the FFR for the stand off frame to the wall. The FFR for stand off frame is now ready to have the stand off frame attached. Stand Off Frame Assembly To assemble the stand off frame please follow the steps below: 1. Take the 2 cross brace pieces and open to form a cross. (fig. 1) 2. Push the cross brace onto the push fasteners on the left and right brackets. (fig. 2) Bracket Cross Brace fig. 1 fig. 2 Push Fastener 19
Fixing the Stand Off Frame onto the FFR for Stand Off Frame The stand off frame can be hooked onto the pins on the FFR. With the stand off frame hanging on the FFR holes can be drilled into the wall, using the holes in the stand off frame as guides. Insert rawl plugs into the drilled holes. Insert and tighten screws and washers to secure the stand off frame to the wall. The stand off frame is now ready to have the TIU mounted to it. Fixing the Stand Off Frame Directly onto the Wall If you are utilising the stand off frame without the FFR please conduct the following steps: 1. Use the cardboard fitting template, supplied with the TIU, level at the intended location of the TIU. The fitting template can be used to mark where the pilot holes are required at the points marked Fixing Point. There are 4 fixing points, drill the holes. 2. Insert rawl plugs into the drilled holes. 3. Partially screw the 4 screws with metal washers into the rawl plugs. 4. Hook the stand off frame over the 4 screws and slide down so that the screw heads are at the top of the slot. 4. Tighten the screws with a screwdriver. The stand off frame is now ready to have the TIU mounted to it. Mounting the TIU to the Stand Off Frame To mount the TIU to the stand off frame, conduct the following steps: 1. Unscrew the 4 bolts and washers from the brackets. These are to be retained to secure the TIU to the stand off frame. 2. Remove the cover from the TIU. Using 2 people to lift, offer up the TIU to the stand-off frame on the wall. 3. Fasten the TIU to the stand-off frame using the bolts and washers provided. The TIU and stand off frame are now wall mounted and the TIU is ready to have the ball valves connected. 20
Connecting the Ball Valves to the TIU The ball valves are supplied loose in a separate box and will have either SharkBite or ¾ FBSP connections. They connect to the TIU via a flat face fibre washer sealed union nut connection. To connect the ball valves to the TIU: 1. Remove the plastic cap from the ball valves, taking care as the cap contains a loose fibre washer inside. 2. Place a fibre washer in each ¾ FBSP connection. 3. Screw the nuts at the top of the TIU onto the ball valves, using the washer to form a seal. Tighten with a spanner. 4. Do not remove the rail clips. These keep the rail connectors in place and prevents the loosening of internal components. The TIU is now ready for the pipework connections. 21
Replacing the Cover To replace the cover of the TIU: 1. Hold the TIU cover by the hand slots. 2. On the inside of the cover there are 4 lugs. Align these with the slots on the TIUs backplate. 3. Align the lugs with the slots, push back and slide the cover downwards, making sure that the bottom of the backplate is inside the cover and that the overpressure relief valve pipe sits in its slot. Pipe in slot Backplate must be inside the cover 22
Hydraulic Connections - Top The following table lists all top connections of the TIU listed from left to right and are also on the fitting template. Backplate 6 1A 1B 1F 1E 1C 1D 2 2 5 7 13 14 Connection Number Description Flow Direction 81A Primary (network) flow Down / into TIU 1B Primary (network) return Up / out of TIU 1F Boosted cold water mains Down / into TIU 1E Domestic hot water Up / out of TIU Not marked on Metered cold water (optional) Up / out of TIU hydraulic diagram 1C Secondary (heating) flow Up / out of TIU 1D Secondary (heating) return Down / into TIU 15 16 Note: If you are using the ¾ FBSP connectors ensure no flux gets into the TIU when soldering or brazing pipework, as the flux will damage the stainless steel pipe. 10 Hydraulic Connections - Bottom Also available with ¾ FBSP connectors 12 There is a connection required at the bottom of the TIU for the overpressure relief pipe (1G). Connect to the 3 ¾ BSP female union nut with an adaptor suitable for your pipework or directly to a tundish. 11 9 Optional First Fix Rail (FFR) 1G When using the optional FFR, all hydraulic connections at the top of the unit can be connected to the pipework prior to fitting the TIU. The pipework can then be pressure tested and flushed, before the TIU is installed. All connections at the top are terminated in ¾ quarter turn ball valves. The connection of the ball valve to the pipework is made via a 22mm SharkBite metal push-fit connectors or ¾ female BSP connection. This allows for a variety of different pipe materials to be used by selecting the correct transition fitting. 23
SharkBite Metal Push-Fit Connectors The First Fix Rail (FFR) and ball valves are supplied with SharkBite metal push-fit connectors as standard. SharkBite is a versatile, easy to fit, secure and watertight brand of push-fit plumbing fittings. SharkBite can connect Copper to PEX pipe, Copper to Carbon Steel pipe, PEX to Polybutylene and chromed copper to PEX pipe. Please note if SharkBite is to be used with chromed copper the pipe must be scribed using a SharkBite scribing tool (Product code SB3415). SharkBite is fully demountable, by using either the demount clip or demount tongs, and instantly reusable. To connect the pipework to the SharkBite ball valves: 1. Cut the pipe square and deburr. 2. Mark insertion depth using the depth marker on the demount clip or use a tape measure. 3. Push pipe into fitting up to the depth mark with a slight twist. If you need to remove the pipe: 1. Demount by using the disconnecting clip (snap clip against release collar and pull pipe at the same time). or 2. Demount by using disconnecting tongs (push tongs over pipe, squeeze tongs together and pull pipe at the same time). To see the full range of SharkBite metal push-fit fittings please visit www.sharkbiteplumbing.co.uk 24
Electrical Installation The TIU is internally pre-wired. There are only 2 external cables requiring connection: the mains supply and the heating controls. All electrical installations must be made to the latest wiring regulations by an approved installer. Mains supply 3A fused/switch 3 or 4 core cable Programmable room thermostat TIU The mains supply should be protected by a 3A fuse or MCB and also have an isolation switch close to the TIU. All electrical connections are made inside the junction box on the left hand side of the terminal strip X1. There are 6 terminals with the one at the bottom being X1/1 and the on at the top X1/6. The mains supply cable connects to: Live: X1/4 Neutral: X1/3 PE: X1/1 The heating controls are not part of the TIU. They are supplied separately. Any standard room thermostat/timer can be used, which will either switch a volt free contact or supply a switched call for heat (supplied from the same mains supply as used for the TIU). The volt free contact from the heating controls connects to: Live: X1/4 Switched Live: X1/6 25
Junction Box FLOW SWITCH CABLE 2 PROG. ROOM STAT SWITCHED LIVE/ BOILER CALL FOR HEAT X1 6 5 BRN BRN BLK2 BLK PUMP LIVE BRN 4 BLK1 BRN CABLE 1 MAINS NEUTRAL BLU BLU PE GRN/YEL IF NECESSARY 3 2 1 BLU BLU BLU GRN/YEL ZONE VALVE BACKPLATE DIVERTER VALVE ACTUATOR Circuit Diagram EXTERNAL SUPPLY L N PE x1/4 x1/3 x1/1 GRN/YEL BACKPLATE BRN x1/4 x1/4 BLK 1 FS ~ x1/1 BLK 2 x1/5 x1/6 EXTERNAL TIMER STAT DIVERTER VALVE ACTUATOR BLK GRN/YEL BRN BRN x1/3 x1/2 ZV BRN BLU BLU x1/2 26
Commissioning - Flushing the Network We recommend to flush and pressure test the network, before the TIU is connected to it. This can be done by using the optional flushing-by-pass valve or by temporarily connecting a piece of pipe between the primary flow and return connections. Ensure that you do not flush through the unit. Radiance TIUs are assembled in a controlled environment and are clean at delivery. Filling the TIU There are 3 independent hydraulic circuits within the TIU. Each one needs to be full before the unit can be commissioned and operated. Ensure that there are no leaks in the installation, each TIU is leak tested prior to dispatch. If any leaks are detected within the TIU then tighten the leaking union connection by utilising 2 spanners: one to hold the nut and the second to hold the fitting. This will prevent any other connections from coming loose. Filling the Primary Circuit 1. Slowly open the ball valve (1A) on the primary flow connection. This will fill the unit from the primary network through the strainer. 2. Next open the primary return ball valve (1B). Any air within the unit will bleed into the network due to the top connections. 1A 1B 1F 1E 1C 1D Filling the Mains Water Circuit 3. Slowly open the ball valve (1D) on the mains water connection. 4. Next open the domestic hot water ball valve (1C). Any air within the unit will be flushed out, when the DHW is run. Filling the Secondary Circuit 5. Slowly open the ball valve (1E) on the secondary return connection. This will fill the unit from the secondary network through the strainer. 6. Next open the secondary flow ball valve (1F). Any air within the unit will bleed into the network due to the top connections. 1A 1B 1F 1E 1C 1D 1A 1B 1F 1E 1C 1D The fill point for the secondary circuit is installed external to the TIU. Fill the secondary circuit to a pressure between 1.0 bar & 1.5 bar. 27
Differential Pressure Control Valve The DPCV is factory set at 30kPa. If there is a requirement to change the setting, insert a 4mm allen key and rotate anti-clockwise as far as possible and the spring is completely loose to achieve the 20kPa. Rotate the allen key clockwise the number of rotations that corresponds with the required differential pressure setting as detailed in the table below. Turns kpa 0 20 1 21 2 22 3 24 4 25 5 26 6 27 7 29 8 30 9 31 10 33 11 34 12 35 13 37 14 38 15 39 16 40 DPCV Open/Close Knob Always ensure that the DPCV is fully open. To do this turn the black knob anti-clockwise until the valve is fully opened. Bleeding the DPCV Ensure that the primary circuit is full and pressurised. Using an 8mm spanner, loosen the capillary tube nut at the connection side of the valve by turning the nut anticlockwise ½ a turn. Allow all air to bleed out of the tube until water begins to appear then tighten the connection by rotating the nut clockwise. 28
Diverter Valve - Disassembly To disassemble the diverter valve conduct the following steps: Fig. 1 Fig. 2 1. Pull the knob off by gripping it and pulling upwards. (fig. 1) 2. Undo the screw, below the knob, with a screwdriver and remove. (fig. 2) Actuator Head Adaptor Fig. 3 Fig. 4 3. Remove the actuator head by gripping it and pulling upwards. (fig. 3) 4. Remove the adaptor. (fig. 4) 29
Assembly To re-assemble the valve conduct the following sequence: Slot Ring Ring Flat edge Flat Edge Fig. 6 Fig. 7 Fig. 5 1. Rotate the shaft to ensure that it is in the correct configuration. The flat edge must be horizontal at the bottom of the valve as per fig. 5. 2. Locate the adaptor back onto the shaft ensuring the slot aligns with the flat edge (fig. 5) and the collar away from the valve. (fig. 6 & 7) Fig. 10 Fig. 8 Fig. 9 3. On the actuator, replace the knob (fig. 8), with the red section showing. Turn the knob clockwise until it stops on the limit (fig.9). Then remove the knob. 4. Replace the actuator head onto the adaptor. (fig. 10) Red section Fig. 11 5. Insert and tighten the screw so that the actuator head is secured onto the body. (fig.11) Fig. 12 6. Replace the knob by pushing it onto the actuator head ensuring to fully insert the knob so that the red section does not show. (fig 12) 30
Thermostatic By-pass Valve & Thermostatic Heating Control Valve The temperature increases by 5 C by each number displayed on the head: 0 = 40 C 1 = 45 C 2 = 50 C 3 = 55 C 4 = 60 C 5 = 65 C 6 = 70 C To adjust the temperature push down on the plastic lock ring and rotate the head to the desired number/temperature. Once the correct temperature has been selected push the lock ring back to its original position to lock the head in place. Temperature indicator Lock ring Zone Valve The flow rate on the zone valve is adjusted by rotating the square face of the brass nut with either a small adjustable spanner or pliers. When adjusting the zone valve the flow rate can be checked on the heat meter (option 5 on the heat meter display) to establish when you have reached the desired flow rate. If the square faces of the brass nut are turned all the way to the top the valve is fully open. When it is rotated all the way to the bottom the valve is fully closed. 31
Thermostatic Mixing Valve The Heatguard thermostatic mixing valve is supplied factory set at 55 C. To adjust this setting proceed as follows: 1. Remove the screw which secures the cap by using a 2.5mm allen key then lift the cap off. 2. With both the hot and cold supplies turned fully on and the terminal fitting (e.g. outlet/tap) is open, adjust the temperature to the required setting by using the cap to turn the adjustment spindle. The temperature will need to be measured at the point of use to ensure it is set correctly. 3. Turn the cap clockwise to decrease or anticlockwise to increase the temperature. Locking Slots 4. Once the correct temperature has been set re-fit the cap, ensuring it is secured through the slots on the locking ring so that the valve cannot be adjusted by the end user. Servicing the Valve 1. Turn off all ball valves at the top of the unit to isolate it from the network. 2. Remove the TMV from the installation by loosening the nuts on the corrugated pipe. 3. To clean the internals of the main TMV body, first remove the cap using a 2.5mm allen key, followed by the plastic locking ring, then finally carefully remove the valve headwork by unscrewing the large hex nut. Make note of the orientation of the parts as they are removed so that they can be reassembled in the correct manner (see fig. 1 for reference). 4. Slide the piston and thermostat assembly out of the TMV body and clean all internal surfaces and O rings with a weak solution of scale remover approved for use with potable water. 5. Using a WRAS approved silicone based waterproof grease, lightly lubricate the O ring in the body and the external surface of the piston. Cap Locking Ring Piston Thermostat Spring fiig. 1 6. After cleaning, re-assemble the TMV. Tighten the pipework onto the valve, with a washer. Exercise, re-set and test the temperature at an outlet to make sure it is at the desired temperature. 32
Pump There are 3 speed settings, which can be selected directly on the circulation pump (5) by pressing the B button. Initially start at setting 1 (the lowest) and balance the radiator system. Only increase the setting, if the pump head is insufficient to heat all radiators on the circuit equally. To adjust the setting press the button on the pump to cycle through the settings. B Heat Meter The symbols shown in the table below indicate the meter s operational status. These status messages appear in the main display. The warning triangle may appear temporarily due to special operating states but this does not indicate the device is malfunctioning. If more than one error appears the sum of the error codes is displayed. E.g. Error 1005 = 1000 and error 5. Symbol Status Event External voltage - Flow present - Attention Symbol flashing: data transmission Symbol constantly displayed: optical interface active Emergency operation Check system/device for error - Replace device Code Error Event 1 Temperature out of measuring range Check temperature 2 Temperature out of measuring range Check temperature 3 Short-circuit return sensor Check temperature 4 Interruption return sensor Check temperature 5 Short-circuit supply sensor Check temperature 6 Interruption supply sensor Check temperature 7 Battery voltage Replace device 8 Hardware error Replace device 9 Hardware error Replace device 10 Error in the measuring system Replace device 20 No water in the measuring tube Check operating pressure 30 Reverse water flow detected Check installation position 40 Air inside the medium Vent system 50 Measured value outside overload range Check dimensioning 100 Hardware error Replace device 800 Wireless interface Replace device 1000 Status end of the battery Replace device 2000 Status initial verification expired Replace device 33
Screen Functions To wake up the meter from sleep mode hold down the grey button for 5 seconds until the display shows. Please note the display refreshes every 4 seconds. 1 2 3 4 5 6 7 8 9 Heat energy (Main display) 1 2 3 4 Segment test 1 Date last billing date 1 Energy Last billing date Volume Flow rate Flow temperature Return temperature Temperature difference Current heat output This is the main display screen which, when the grey button is pressed, will scroll through the different screens (1-9). On the last screen, the current output screen, press the grey button to return to the first screen (the display test). Staying on the same screen for more than 2 minutes will return to the first screen. Display Test This screen shows all of the symbols on the display to ensure they are functioning. It alternates between all segments on and all segments off. Date Last Billing Date This shows the billing date. Energy Last Billing Date This is the energy, in megawatt hours (MWh) recorded at the last billing date. Recorded Volume This shows the total volume in metres cubed (m³) through the heat meter since it has been installed Flow Rate This shows the current flow rate in cubic metres per hour (m³/h). Flow Temperature This shows the flow temperature entering the TIU in degrees Celsius ( C). Return Temperature This shows the return temperature returning from the TIU in C. Temperature Difference This shows the temperature difference between the flow & return in C. Current Heat Output This shows the current heat output in kilowatts (kw). For further settings please refer to the separate heat meter manual supplied with the TIU. 34
Maintenance The TIU should be checked and serviced at least once a year. Remove the cover and check for any possible leaks. If a leak is found tighten the connection. To test the TIU is working correctly run a hot water tap to test the DHW production and then switch on the heating to test the heating circuit. This will test the circulation pump and diverter and zone valve. There is no need to maintain the expansion vessel. The expansion vessel is of a unique, patented spring loaded design and does not ustilise an air cushion to generate pressure on the expansion membrane. Because of this, the expansion vessel is totally self regulating and maintenance free. Strainer Strainer The only components requiring service inside the TIU are the line strainers on the primary flow and secondary return connection and the TMV (please see page 32 for TMV maintenance guidance). To check and clean the line strainers conduct the following procedures: 1. Remove the cover of the TIU and isolate the electrical supply to the unit. 2. Turn off all valves at the top of the unit to isolate it from the pipe work. Nut Gauze 3. Unscrew the nut of each of the strainer catching any small amounts of water, which may leak from the strainer. 4. Remove the gauze from the strainer, check and clean under clean running water if necessary (using a small brush, such as a toothbrush, can help to dislodge debris). 5. Re-fit the clean gauze, the o-ring sealing the nut should be checked and can be re-used if ok and screw the nut back onto the strainer. 6. Open all valves and check for leaks. 7. Switch on the electrical supply to the unit and test the hot water and heating performance. 8. Replace the TIU cover. 35
Troubleshooting Overview and Procedure This troubleshooting guide has been designed to help identify any possible problems and provide the solution. It is important to gather as much detailed information as possible when looking for a fault so that you can correctly identify where the problem is located. Be aware the problem may not always be within the TIU. If the heat network is supplying a primary flow temperature of only 55 C (below the minimum required temperature of 65 C) the TIU will not be capable of supplying the required DHW or heating. Check and record the following parameters utilising the heat meter: Primary flow temperature Primary flow rate with heating on Primary flow rate with DHW on Establish what exactly is not working: Is only the heating working, only the DHW working or are both the heating and DHW not working? Is the heating cold or just tepid? Is the DHW cold or just tepid? If the heating is working you will see: The circulation pump running with at least one green LED on at the pump. The primary zone valve open showing the red indicator clearly protruding from the actuator body by approx. 3mm (this can take up to 3 minutes after switching the heating on) If the DHW is on you will see: The diverter valve actuator is/has rotated the black central knob counter clockwise. The red mark on the knob has/will move from the 5 o clock position to the 1 o clock position. This is important information to help identify where the issue is. This information will permit you to work through the flow chart overleaf which will guide you to possible issues and solutions. If you are still experiencing issues after working through the flowchart please contact the RWC UK technical department on 01386 712400 or email technical@rwc.co.uk quoting the part number (RTIU702XXX) which is located on the backplate of the TIU. 36