warm water underfloor heating installation manual design innovation expertise service v4b-aug 08 Nu-Heat
System Ref: Introduction installation manual for nu-heat warm water underfloor heating with fastflo tubing and optiflo control with a combination boiler, user-supplied cylinder or energymaster cylinder It is a condition of the warranty that the Certificate of Installation and Commissioning application form is completed and returned to Nu-Heat once the system is fully commissioned. This set of manuals gives all the information needed to install your Nu-Heat warm water underfloor heating system. In order for the process to be achieved quickly and easily the principle of underfloor heating should be understood. The following pages have comprehensive diagrams showing the purpose of each system component and its position in the overall scheme. Parts shown in colour are supplied by Nu-Heat and those shown in outline are generally supplied by others; for example if a traditional radiator system is fitted alongside the underfloor heating, control of the radiators is via a programmable room thermostat or timeclock with individual thermostatic radiator valves as required. These parts are not supplied by Nu-Heat. System specification and electrical wiring details are supplied in the separate manuals in this folder. The boiler heat requirement for your underfloor heating system is noted on the system design supplied together with the number and lengths of tubing coils and their spacings for each individual room zone. The boiler should be chosen to match the total load for the property. Attention to the advice given in this manual will help to ensure a trouble-free and effective installation. The requirements of the relevant British Standards, Water Bye-laws and other regulations should always be met. If there is any aspect of the installation that you do not understand, please contact Nu-Heat Customer Support, quoting your system reference number, for advice. In line with the company policy of product development, Nu-Heat reserves the right to supply different components to those shown. This manual is the copyright of Nu-Heat. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written permission of Nu-Heat.
Contents Section Contents 1.1 Checklist 1.2 Recommended installation sequence 1.3 System components: Underfloor heating Optional plumbing components 1.4 Optiflo manifolds 1.5 Pump Module: Direct mounted pump module Remote mounted pump module 1.6 Alupex 1.7 Connecting to the Optiflo Manifold 2.1 Installation details 2.2 Filling, flushing and pressure testing room zones 3.1 Installing the EnergyMaster cylinder: Components EnergyMaster2 cylinder 3.2 Temperature/pressure relief valve discharge 3.3 Connection position of secondary hot water loop 3.4 Filling the EnergyMaster cylinder 3.5 EnergyMaster hot water supply 4.1 Filling the boiler and heating system pipework Filling the boiler Filling the heating system pipework with a Direct Mounted Pump Module Filling the heating system pipework with a Remote Mounted Pump Module 4.2 Setting flow rates and Commissioning 5.1 Commissioning the EnergyMaster2 cylinder (where fitted) 6.1 Aquastar hot water loop 7.1 Problem solving Underfloor heating 7.2 Problem solving EnergyMaster2 cylinder
1.1 Checklist 1.1 Checklist Floor heights: Check that the height of the subfloor is correct for the depth of construction needed to incorporate the underfloor heating. This is especially important if more than one construction type or different floor finishes are used on the same floor. Information on your specific A3 Floor Constructions is provided as part of the A3 System Information. Timber frame buildings: Check that the sole-plate depth will accommodate the appropriate Nu-Heat floor construction. If the tubing is to be fitted from below in a suspended timber first floor, any cross-blocking (noggins) must be reduced in height by 30mm to allow the tubing to pass through and, where possible, any joist notching/service holes must be drilled before laying the deck. Floor insulation materials: Ground floor insulation must meet Building Regulations 2006, Part L. A minimum requirement for ground floors is 75mm of PIR insulation (Celotex, Kingspan, Ecotherm, Xtratherm), or 110mm of EPS (Jablite, etc). Advice on this should be sought from your architect, builder or local authority planning department. For floating floors Nu-Heat supplies EHDN grade polystyrene tracked to accept the heat transfer plates and Fastflo tubing but this is not intended to meet Part L requirements for ground floors. If you are installing from below in a suspended timber floor using mineral wool insulation, certain floor constructions require a separate foil facing, which is supplied by Nu-Heat (see the A3 Floor Construction detail at the beginning of this folder). All other insulation materials are readily available from builders merchants. Always read the floor construction information in the A3 System Information before starting the tube installation. It is the responsibility of the customer to make sure that insulation levels conform to the relevant British Standard and any other applicable building code. Mains water supply: Check that the performance of the mains supply matches the requirements of the household. Refer to Section 3.1 for the requirements of the EnergyMaster cylinder. Fastflo tubing: The number and lengths of tubing coils and their spacings and flow rates for each individual room zone are detailed on the A3 Tube Layout. Avoiding damage to the tubing: If it is necessary to store the tubing, keep it dry, out of direct sunlight and away from sharp objects or possible chemical spillage. Avoid any soldering near Fastflo tubing as overheating may result in failure. Tubing that may become frozen before or during installation or while the screed dries should have anti-freeze added and be thoroughly flushed afterwards. Do not kink the tube by over bending. Boiler: The heat loading for your underfloor heating system is indicated on the A3 System Information. Please refer to the boiler manufacturer s recommendations for installing and commissioning the boiler. Check the boiler installation requirements with the manufacturer as in some cases a by-pass valve may be recommended between flow and return pipework. Cooker-boilers may also have additional requirements; always refer to manufacturer s information. See you A3 System Information for advice on expansion vessel sizing. Insulation of pipework: The sensible use of insulation is recommended on the flow and return pipework between the boiler, cylinder and Optiflo manifolds. Domestic hot water pipework should also be insulated, particularly on a pumped loop. Ensure that the incoming cold main is separated from any hot pipework to prevent heat transfer. Taking delivery: Please check your delivery against the delivery note and report any discrepancies within 7 days of receipt. Warranty: In order to validate the warranty the Commissioning Checklist & Warranty Application form in the Commissioning Pack attached to this manual must be completed by the installer and returned to Nu-Heat.
1.2 Recommended installation sequence The general sequence of installation is as shown in this manual. Before starting check the positions of the main components such as Optiflo manifolds and Pump Modules as agreed at the system design stage and noted on the plans. Make sure that room dimensions and joist spacings have not changed as this could affect the amounts of tube required. Full dimensions of the components supplied are given in this manual, and suggested positions for components can be found in the A3 System Information and A3 Manifold & Zone Information. 1.2 Installation sequence 1. First-fix the main wiring. The positioning of the boiler, cylinder (if used), circulation pump(s), thermostats and Optiflo wiring centres should be agreed between the customer or architect, and the Nu-Heat designer. Please refer to the A3 System Information and A3 Manifold & Zone Information for exact component locations this can only be confirmed once the initial design work is complete. Please refer to the separate electrical manual for detailed wiring diagrams. 2. First fix the domestic services if they are to run beneath the floor insulation. 3. Lay the floor insulation. 4. Fix the Optiflo manifolds and circulation pump(s) in position. See Sections 1.4 and 1.5 for fixing instructions. See A3 System Information for locations. The manifolds are reversible to allow right- or left-handed pipe connection. 5. 10mm Fastflo systems only First-fix the 18mm Alupex pipework between the Optiflo manifolds and room distributor positions. 6. Install and pressure test the underfloor heating tube. 7. Fit the primary flow and return pipework between the boiler, cylinder (if used), circulation pump(s), and the Optiflo manifolds. Follow the A3 System Information at the beginning of this folder. Fit the boiler and cylinder if not done earlier. 8. Fit the remaining hot and cold domestic water pipework. If an Aquastar hot water loop has been specified, refer to the diagrams in Section 6 for details. 9. Commissioning can only take place after all electrical installation has been completed and checked by the electrician (see Electrical Manual).
1.3 System components 1.3 System components Pump Module This comprises of the pump and temperature blending valve. Depending on the system design there may be Direct Mounted Pump Modules connected directly to the manifolds, or centrally located Remote Mounted Pump Modules feeding multiple manifolds, or a combination of these. Project-specific detail is contained in the A3 System Information. The floor heating pump circulates the hot water from the boiler to the Optiflo manifold(s) and around the floor heating tube. The temperature blending valve mixes hot boiler water with the colder water returning from the underfloor heating to achieve the design temperature, as set on the valve head. Both assemblies can be connected left or right handed, see sections 1.5 for further details. Optiflo Manifold may be connected either left or right-handed The stainless-steel Optiflo manifolds are fed from the Pump Module. When hot water is required by the underfloor heating system, a valve on the manifold opens and hot water is pumped through to the tubing in the floor. The flow rate of the water is shown on a flow gauge on the manifold. When the air temperature of each room reaches the required level, the wall thermostat switches off its corresponding valve actuator on the manifold. Manifolds are available with up to 12 ports. See Section 1.4. 18mm Alupex flow and return pipe (10mm & 14mm Fastflo systems only) This larger, aluminium-cored pipe runs between the Optiflo manifold and the Fastflo tube in the floor. It is important to label each length of pipe correctly with its zone number and room name when it is connected to the manifold as they must be clearly identified in order for the wiring to be successfully completed. See Section 1.6. Distributor Module 10mm Fastflo Distributor assemblies take water from the 18mm Alupex pipe connected to the Optiflo manifold and direct it to 10mm Fastflo tubes in individual room zones. They can be joined and fitted side-by-side to provide additional ports as specified in the A3 Tube Layout. They are supplied with blanking plugs for unused ports. For screeded floors a moulded box is provided to protect internal components. Further information can be found with the A3 Floor Constructions. 14mm Fastflo In certain floor constructions a zone may be fed by 18mm Alupex, and then Distributor Modules can be used to feed two 14mm Fastflo pipes. Cliptrack Cliptrack is used to secure Fastflo tube in place on the floor. The tubing is held at the correct spacings to ensure the room reaches its set temperature efficiently, note that these spacings are detailed on the A3 Tube Layout drawings, and may vary from room to room. Cliptrack can also be used when fitting tubing from below to first floor suspended timber floors. Details are included in the A3 Floor Constructions at the front of this folder. Note: Design of Cliptrack may vary according to floor type and pipe size. 14mm Fastflo & 16mm Alupex floor tube The floor heating tube is connected to the flow and return ports on the Optiflo manifold. The number of coils of tube and the spacing used in each zone are noted on the A3 Tube Layout. Detailed instructions on how to lay the tubing in different A3 Floor Constructions are included at the front of this folder. 10mm Fastflo floor tube Fastflo-10 is connected to the flow and return ports of the distributors, which are fed by 18mm Alupex connected to the Optiflo manifold. The number of coils of tube and the spacing used in each zone are noted on the A3 Tube Layout. Detailed instructions on how to lay the tubing in different floor constructions are included at the front of this folder.
1.3 System components Optional plumbing components Aquastar Secondary Hot Water Loop Hot water pump and timer The hot water pump is connected to the return of the domestic hot water loop. It has a timer to allow it to operate independently. It is important to connect the pump with the arrow pointing in the direction of flow back to the cylinder. Additional features include a water temperature control thermostat and non-return valve with isolator. The pump will be sized depending on the length of the loop. Hot water loop expansion vessel The hot water loop expansion vessel, pressure gauge and pressure relief valve are connected to the domestic hot water loop return. The 2-litre expansion vessel has a pre-charged air pressure of 4 bar which must be checked and adjusted if necessary on commissioning. There is a combined 10 bar pressure gauge and 6 bar pressure relief valve. If the incoming mains pressure exceeds 3.5 bar, a pressure reducing valve the same size as the incoming mains pipe must be fitted. 1.3 Optional components Drain valve The drain valve is fitted on the return pipework of the hot water loop. It enables the system to be drained for necessary maintenance. This valve is also used to purge air from the return pipework when initial filling and system commissioning takes place. For instructions on installing the Aquastar hot water loop see Section 6. Optional heated towel rails Heated towel rails Heated towel rails can be installed on the hot water loop for both EnergyMaster and user-supplied cylinders. This has the advantage of not having to run a separate circuit from the heating system. To prevent corrosion by the mains water, any towel rail fitted must be manufactured from rust-free material. They operate all year round whether the heating is in use or not as they are entirely independent of the heating system. Note: When towel rails are fitted to the hot water loop of an EnergyMaster cylinder the return must be connected as shown on the plumbing schematic in the A3 System Information. A comprehensive range of suitable heated towel rails is available through Nu-Heat. For further details talk to our Sales Team on 01404 549770 or visit www.towelrails.co.uk For instructions on installing towel rails, see Section 6.
1.4 Optiflo manifolds 1.4 Optiflo manifolds Optiflo manifolds are supplied boxed and ready assembled, except for the temperature gauges which must be pushed into the pocket on each manifold rail. However you may require to change the handing of the manifold, or orientate the outlets upwards. Orientate manifold to suit installation left-handed Right- handed Upside down. 1. Unscrew the manifold-rail mounting clamps, turn the manifold to the correct orientation and re-fit the mounting clamps. Note: The manifold brackets are designed such that one rail is offset for the pipes to pass behind it - the brackets should be orientated to take account of the direction of the pipes. The Supply (flow) manifold must be the rail with the flow gauges. 2. Remove the temperature gauges (these are a press fit), unscrew the boss, and the blanking screw on the reverse. 3. Refit the boss on the front of the rail, and the blanking screw on the back. Refit the temperature gauges. If the manifold is to be fed from a Direct Mounted Pump Module then this is connected to the captive nuts using the fibre washers supplied to give a watertight seal. A proprietary sealing compound can be used in addition. With a Direct Mounted Pump Module the shut-off valves are connected in the flow and return pipes on the boiler side of the Pump Module. If the manifold(s) are to be fed from a Remote Mounted Pump Module then shut-off valves should be connected directly to the captive nuts on the manifold, using the fibre washers supplied to give a watertight seal. A proprietary sealant may be used in addition to this. The female end of the valve will accept the brass compression to male iron fitting that is supplied. The threaded connection and the compression fitting should be made using either a proprietary sealing compound, or PTFE tape. Connection valves and fittings are supplied in a separate kit. Positioning Place manifolds where they are easily accessible as settings may need to be changed. The size of manifolds varies depending on the number of room zones being connected and the cupboard or casing needs to be big enough to cater for this. See the A3 System Information for detailed location. 600mm minimum to floor 200mm 28mm Installation 1. Screw the manifold assembly firmly to the wall by the fixing brackets. Position at least 250mm from floor. 50mm Note: If necessary, remove the lower manifold to make access easier when fitting the pipe to the upper manifold. 50mm Length varies 95mm Number of ports: 2 3 4 5 6 7 8 9 10 11 12 Length in mm: 195 245 295 345 395 445 495 545 595 645 695
1.5 Pump Modules Depending on the design of system there may be Direct Mounted Pump Modules connected directly to the manifolds, or a centrally located Remote Mounted Pump Module feeding multiple manifolds, or a combination of these. Refer to the A3 System Information for system specific information. Direct Mounted Pump Module 200mm 270mm The Direct Mounted Pump Module connects straight onto the manifold. Refer to the A3 System Information for manifold and Pump Module positions. 1.5 Pump modules 58mm 140mm 100mm Reversing the direction of the pump As supplied the pump will connect to the left-hand end of the manifold. To connect the Pump Module to the right-hand end: 2 3 1. Reverse the manifold on it s brackets, and reverse the temperature gauges see section 1.4 opposite 4 2. Remove the mixing valve castings from the bottom of the pump by undoing the pump nut. Take care not to lose or damage the rubber washer. rotate 180 3. The mixer casting will need the pump connection to be moved to the opposite side. Using a spanner unscrew the blanking cap on the underside of the mixer valve casting. Note: this has a LEFT-HAND THREAD 5 4. Using a spanner unscrew the pump connection from the top side of the mixer valve casting. Note: this has a LEFT-HAND THREAD 5. Replace the blanking cap and pump connection such that the pump connection is on top when the single connection for the manifold cold return is on the left, and the adjustment knob is at the front (note that flow direction is indicated by arrows on the casting). 6. Remount the casting onto the pump, refitting the rubber washer. Loosen the top casting and turn this to face left. When attaching the manifold to the pump module make sure that the supplied fibre washer is fitted. A proprietary sealant may be used in addition to this. The boiler flow and return connections on the pump module will accept the 3/4 ball valves supplied with the pump module. The threaded connection should be made using either a proprietary sealing compound, or PTFE tape. 3/4 male iron to 22mm compression fittings are supplied to connect the flow and return pipes to the ball valves.
1.5 Pump Modules continued Remote Mounted Pump Module 1.5 Pump modules Boiler flow Pump module UFH flow Manifold UFH return Boiler return The Remote Mounted Pump Module is located remotely from the manifold(s). Refer to the A3 System Information for manifold and Pump Module positions. The Remote Mounted Pump Module should be screwed to the wall using the holes provided in the backplate. A separate manifold connection pack is supplied which contains valves and compression fittings. The male end of these valve fits onto the captive nut on the manifold rail, using the fibre washer supplied to create a watertight seal. A proprietary sealant may be used in addition to this. The female end of the valve will accept the brass compression to male iron fitting that is supplied. The threaded connection and the compression fitting should be made using either a proprietary sealing compound, or PTFE tape. The Pump Module has 28mm stub ends to connect to your boiler, and manifold supply pipework. These may be connected using either compression, push-fit or soldered fittings. Recommended pipe sizing to and from the Pump Module are given on the A3 System Information at the beginning of this folder. Reversing the direction of the remote pump As supplied the Pump Module will receive the boiler flow and return from the left hand side, feeding the manifold(s) from the right-hand side. It may be reversed by rotating the Pump Module through 180 before fixing in position. UFH flow Boiler return UFH return Boiler flow 1 rotate through 180 Note: At some point between the Pump Module and the Optiflo manifold, the pipe work must cross over to ensure that the flow from the boiler connects to the flow (upper) manifold and the boiler return pipework connects to the return (lower) manifold as shown.
1.6 Alupex For systems using 10mm Fastflo tube, as well as some 14mm constructions, 18mm Alupex pipe is provided for the flow and return pipework between the Optiflo manifolds and the distributors in each zone. The 18mm pipe should follow the easiest, most direct route. Where appropriate it should be tracked into the insulation below the Fastflo tube using a router. In certain A3 Floor Constructions clips are provided to secure the Alupex onto the insulation. See also the A3 Floor Construction detail at the front of this folder. This 18mm pipe can be carefully bent to form curves of approximately 100mm radius. If right-angle elbows are required for tight turns, they can be purchased from Nu-Heat. 18mm Alupex 18mm pipe fitting Universal joiner Port splitter 14mm distributor module 1.6 Alupex In 14mm systems a Distributor Module is sometimes used to connect from 18mm Alupex to a pair of 14mm Fastflo pipes. Refer to the A3 Floor Constructions in the A3 System Information for details. For systems using only plastic(pex) pipe, if this is to be routed through a stud wall then a metallic tape should be located along the same route to make the pipe traceable. The tape is best attached to the wall behind the pipe, rather than to the pipe itself, as some adhesives affect the material properties of the pipe. 14mm pipe fitting 14mm Fastflo 1.7 Connecting to the Optiflo Manifold 14mm Pex pipe with 12mm internal diameter or 16mm Alupex pipe with1 2mm internal diameter or 18mm Alupex pipe with 14mm internal diameter calibration tool 1. Re-shape the ends of the pipe using the calibration tool, opening out the ends to allow fitting of the insert without displacing the O-rings. Note: Do not forget to place the nut and olive over the pipe before fitting the insert. 1.7 Connect to the manifold Important! Dining Room Zone 3 Dining Room Zone 3 2 connect Nu-Heat 2. Connect the flow pipe to the ports on the upper manifold with the fittings supplied the lower manifold may be removed to make this easier. 3. Important: It is critical to clearly mark each pipe with its correct zone number and room name with the marker pen provided. The electrician will need this information to wire the system correctly. See the A3 Manifold & Zone Information for more information. 4. Re-attach the lower manifold to the fixing brackets (if removed). 5. Connect the return pipe to the correct ports in the same way.
2.1 Installation details 2.1 Installation details For installation details referring to the specific floor types and underfloor heating tube layouts within your property, please refer to the A3 Tube Layouts and A3 Floor Constructions at the beginning of this folder. 2.2 Filling, flushing and pressure testing room zones Pressure testing room zones Zones must be pressure tested prior to screeding or covering the tube. Follow the full procedure for each zone and for each manifold assembly. Note: Any unused ports on the Optiflo manifold can be isolated for future use by using the blue cap to close the return and the screwing down the flow adjustment on the supply manifold. Filling, flushing and pressure testing 1. Close the isolating ball valves that are either connected directly to the manifold, or connected just before the Direct Mounted Pump Module 2. Isolate all zones by screwing down all the blue protection caps hand tight. 3. Fully open all the flow adjusters on the supply (top) manifold by lifting the red locking collar which may then be used to turn the black collar fully anti-clockwise. open valve 4 6 5 7 4. Remove the blanking cap from the filling valve on the flow (upper) manifold. Fit the hose connection nozzle (from the tools and accessories pack), and connect a suitable hose from the mains water supply. Open the filling valve using key on the blanking cap. 5. Similarly fix a suitable hose to the drain valve on the return (lower) manifold. 6. Fully loosen the protection cap from the first zone to be filled. 7. Open the tap on the mains water supply and open the drain valve on the return (lower) manifold using key on the blanking cap. 8. Run the water until all air is expelled from the pipe. This will take approx. 5 minutes. Tip: If the outflow is run into a bucket then air bubbles will be detectable.
open 9 10 close 12 close 2.2 Fill/flush/pressure test 9. Open the next zone. 10. Close the flushed zone. 11. Repeat steps 8 10 for all zones on each manifold. 12. Close the drain valve on the return (lower) manifold. 13. Allow the pressure to rise to a maximum of 6 bar 14 close 16 release pressure 14. When the correct pressure is reached, close the filling valve. 15. All zones are now fully pressurised and should be left for at least 8 hours. Due to expansion and air temperature variations, a pressure drop of up to approximately 0.5 bar may occur. If greater pressure drops are experienced, thoroughly check all pipes and joints for evidence of water loss. If none is found, there may still be air in the system and the filling and flushing procedure should be repeated. 16. After testing, reduce the pressure to 1 bar-static by releasing the water from the drain valve on the return(lower) manifold. Note: The floor heating tube must be left under pressure whilst floors are screeded. 1 bar is sufficient.
3.1 EnergyMaster cylinder 1 2 3 4 5 3.1 Installing the EnergyMaster Cylinder Components EnergyMaster cylinder Please refer to your A3 System Design for your specific plumbing schematic. The EnergyMaster cylinder stores water for both the floor heating and the production of domestic hot water. If the temperature of the water in the cylinder falls below the level set on the cylinder thermostat, the boiler is turned on and hot water is circulated into the body of the cylinder to replenish the store. In larger properties either a larger cylinder, or twin cylinders may be recommended to ensure an adequate supply of hot water. The positioning of the cylinder within the property will have been agreed after consultation with the Nu-Heat designer. Detailed dimensions, fixing and connections are given in this section. 1. Automatic air vent 6 2. Temperature / Pressure relief valve (factory fitted) 3. Chrome pipework assembly (trim to length) 7 8 4. Hot water blending valve 5. Shock arrestor connection/connection point for hot water loop return when no towel rails are fitted 6. Flow switch 7. Cylinder thermostat 8. 3kW immersion heater If the EnergyMaster cylinder is used without an Aquastar hot water loop then a shock arrestor is supplied. This vessel absorbs the small amount of expansion in the domestic hot water pipework when the system is hot and must be checked and set to 4-bar when the system is cold, at commissioning stage. Rapid vent screw Bleed screw Auto air vent operation and maintenance For rapid venting when filling the cylinder remove both caps and depress the valve under the red cap with a screwdriver. Replace the red cap when the system is full. During normal operation the cylinder is vented by leaving the black bleed cap loose, this allows stray pockets of air to escape automatically and should be checked regularly. Important: to prevent cylinder collapse when draining down the system ensure the rapid venting valve is depressed or the air vent connections loosened. Temperature/pressure relief valve If, in the unlikely event of failure of all other safety devices, the cylinder reaches high pressure or temperature then water will be discharged by this valve. The outlet from this valve should be safely taken to waste (see information in Section 3.2). The valve should be manually operated during the annual servicing by turning the black knob in order to check that it is free to function.
Shunt pump, valves and bends Mounted on the EnergyMaster cylinder and controlled by the flow switch, this pump circulates stored boiler water through the domestic hot water heat exchanger giving mains-pressure hot water on demand. Important: Arrow indicates direction of water flow. 3.1 EnergyMaster cylinder Flow switch The flow switch detects the flow of water into the EnergyMaster cylinder s internal heat exchanger. The switch operates the shunt pump, ensuring that the heat exchanger can work at its maximum capacity. The flow switch must be fitted in the orientation shown, with the arrow pointing upwards. Isolating valve and strainer The in-line 22mm isolating ball valve with filter is fitted on the cold mains supply to the EnergyMaster cylinder. It prevents grit getting into the cylinder and enables the cold water supply to the cylinder to be shut off if necessary. It must be fitted with the trap below the pipework. Restrict the incoming mains cold water flow rate to between 22 and 27 litres/min. for 210 litre cylinders, 36 and 40 litres/min. for 300 litre cylinders and between 54 and 63 litres/min. in total. Cylinder zone valve The zone valve controls the flow of water from the boiler to the cylinder. It opens when the cylinder thermostat calls for heat. Ensure the valve is positioned on the boiler flow pipe as shown in the A3 System Information. This valve must be fitted in all cases as it acts as protection against overheating. Expansion vessel and filling loop assembly The expansion vessel forms part of the filling loop assembly. It accommodates boiler and cylinder water expansion when the system is hot. Use in addition to any internal systemboiler vessels to accommodate the additional expansion of the EnergyMaster cylinder water volume. It is important to note: before fitting the expansion vessel the air pressure must be reset. Refer to A3 System Information. 1. Connection to boiler primaries 1 2 3 4 5 6 2. Pressure gauge 3. Pressure relief valve 4. Discharge to waste 5. Non-return valve 6. Isolating valves (2) 7. 15mm cold mains in 8. 15mm Pressure reducing valve adjusted to 1-bar maximum fill pressure 6 7 8 9. Air valve connection (for charging and checking pre-charged air pressure) 10. Expansion vessel 9 10
3.1 EnergyMaster cylinder 3.1 EnergyMaster2 cylinder Performance (figures shown in brackets are for 300 litre cylinder) The EnergyMaster cylinder is designed to provide a maximum flow rate of 26(40)l/min, raising mains cold water through 40 C at full duty. Mains water supply The cylinder should take its mains water feed before all other cold water draw-offs, above the stop cock. If the mains pressure exceeds 3.5-bar it should be limited to this figure by a pressure reducing valve (not supplied) equal to the size of the connecting pipework, fitted after the incoming stopcock and before any draw-off points. A mains water input of 22 27 (30 40) l/min (or double for dual cylinders) is required at minimum static pressure of 2-bar. Where the supply is inadequate but the incoming mains pressure is over 2-bar it can be boosted with a purpose-designed accumulator vessel. Please contact Nu-Heat for details. Pipework The minimum size of copper pipework to be used for mains water connections to and from the cylinder is 22mm for single cylinder and 28mm for dual cylinder systems and for the 300 litre cylinder. Notes: If the EnergyMaster cylinder has to be drained, either depress the red capped fast-purge valve on the auto air vent or remove the entire auto air vent. Failure to do this could result in major damage and collapse of the cylinder. Solar coil cylinders will have additional connections for the solar coil. Minimum height of cupboard Preferred width of cupboard 1185mm 2270mm for dual cylinder systems Minimum cupboard depth 675 (800)mm Diameter 540 (600)mm EnergyMaster Cylinder capacity 210 (300) litres Cylinder weight when full 272 (400) kg Cylinder weight when empty 62 (100) kg Overall height Cylinder height Boiler flow 28mm Domestic hot water out (22mm connection) 1635 (1880)mm 1320 (1538)mm 260 (288)mm Shunt pump & valves Boiler return Drain-off 28mm 22mm 22mm 1 /2 22mm 28mm 28mm Shock arrestor connection Flow switch mains cold water in Floor heating flow Floor heating return 200 (228)mm 500 (528)mm Approx. 785 (843)mm 930 (1128)mm Approx. 1100 (1313)mm 1508 (1751)mm 1625 (1816)mm
3.2 Temperature/pressure relief valve discharge The pipe work that takes any discharge from the temperature/pressure relief valve should be fitted in copper. A tundish is not a mandatory requirement, but may be fitted if desired. In either case the outlet of the pipe should be taken to a safe place, as any water/steam released is a scald hazard. Such a safe place would be below a fixed grate to a trapped gully. Note that the discharge will be either very hot water or steam, that will cause damage to certain plastics or asphalt, etc. The pipe work should be sized so as not to restrict the discharge. The diameter should be at least as large as the outlet of the valve. If the length of pipe is greater than 9m then the next size up is required (i.e if a 15mm (1/2 ) valve then 22mm pipe work), and if longer than 18m then two sizes larger, and so-on. Any bends and elbows also present a pressure drop, and these must be accounted for by assigning an equivalent pipe length as given in the table below. 3.2 EnergyMaster cylinder 1/2 Valve: Pipe size (mm) Max. pipe length based Equivalent resistance on straight length (m) of bend or elbow (m) 15 9 0.8 22 18 1.0 28 27 1.4 The pipe should drop continuously away from the valve. Note: If a tundish is fitted then the outflow from it should be made in the next largest size from the inlet, again increasing the size for each additional 9m in length, including bend or elbow equivalent length. 3.3 Connection position of secondary hot water loop Auto air vent Hot water to taps Secondary Hot Water Loop return supplied separately NRV Mains cold water Immersion heater Drain-off Underfloor heating Flow Return
3.3 EnergyMaster cylinder 3.4 Filling the EnergyMaster cylinder The boiler filling loop can be used to fill the cylinder. Whilst filling the cylinder it is important that the fast purge valve under the red cap of the Automatic Air Vent is depressed. Alternatively the air vent may be removed until the cylinder is nearly full, and then the fast purge should be used. 3.5 EnergyMaster hot water supply Domestic hot water temperature blending valve The domestic hot water blending valve should be fitted to the EnergyMaster cylinder. It is suppled pre-set to 43 C however BS6700 recommends that water be distributed at no less than 45 C. If a hot water loop is to be used then the HSC s Legionnaires disease: The control of legionella bacteria in water systems Approved Code of Practice and Guidance says that this temperature should be 50 C or more. If the temperature of circulation necessary to achieve this poses a significant risk of scalding then the temperature should be blended as close to the output as possible. In order to set a different temperature, do as follows: Remove the screw securing the blue (or red on the 300 litre cylinder) knob to the valve. Remove both the blue (red) knob and the locking ring. Domestic hot water temperature blending valve (210 litre) Replace the blue (red) knob temporarily. Open a tap and adjust the set temperature of the valve as required (anti clockwise to increase and clockwise to decrease). Remove the blue (red) knob and refit the locking ring. Locate the tab on the inner face of the blue (red) knob into the retainer in the locking collar and secure the knob with the socket screw. Maintenance of the domestic hot water blending valve The valve should be checked and cleaned annually. If the cylinder s domestic hot water pipe is hot and the blending valve outlet pipe cold it is possible that there is a build up of scale within the valve. To strip down the valve and clean: Drain the domestic hot water system. 35 MIN MAX 65 Domestic hot water temperature blending valve (300 litre) Isolate the valve and remove the blue (red) knob and locking ring. Unscrew the large hexagonal cap and slide out the interior parts of the valve. (Note the orientation of the parts to aid reassembly.) 3.4 EnergyMaster cylinder After cleaning and reassembling, the valve should be reset and tested. Balancing domestic hot and cold water supplies Balance the hot and cold water to all taps according to normal practice. Limescale prevention Important: In semi-hard and hard-water areas where typically CaCo 3 exceeds 200ppm, the incoming water should be treated appropriately. Where extreme water conditions exist the use of a high pressure water softener is recommended. Please ensure the model chosen will not give significant water pressure and flow rate drops. Contact the local water authority for details.
4.1 Filling the boiler and heating system pipework Filling the boiler Fill the boiler via the boiler filling loop whilst venting the system and following the boiler manufacturer s instructions. The system should be cleansed and flushed in accordance with BS7593:1992 to remove all flux residue and other debris. Filling the heating system pipework with a Direct Mounted Pump Module At the first manifold: 4.1 Filling the system 3 2 open connect 4 fill the system 5 close 1 open 2 connect 1. Open the flow isolation valve. 2. Find the hose tails from the tools and accessories pack and connect to the fill and flush hoses. 3. Use the cap end to open the drain cock on the flow (upper) manifold. 4. Fill the system via the boiler filling loop and run water through until the flow from the drain hose is free from air bubbles. 5. Close the boiler filling loop and drain cock. remove 7 6 close 6 open 8 connect 7 open 10 open 11 set temperature 6. Shut the flow isolation valve and open the return valve. 7. Remove the hose from the upper drain cock and connect it to the return (lower) drain cock. 8. Use the cap end to open the drain cock on the return (lower) manifold. 9. Repeat steps 4 and 5. 10. Open the flow isolation valve. 11. The temperature control valve on the pump module should be set to minimum. 12. Repeat steps 1 to 11 at each manifold that is fitted with a Direct Mounted Pump Module. Note: The system cold working pressure is 1.0 bar. When the system pressure has been set, isolate the filling loop and disconnect in accordance with water authority regulations
4.1 Filling the boiler and heating system pipework 4.1 Filling the system Filling the heating system pipework with an Remote Mounted Pump Module At the first manifold: 1 open 3 2 open connect 3 remove 1. Open the flow isolation valve. 2. Find the hose tails from the tools and accessories pack and connect to the fill and flush hoses. 4. Remove the head from the blending valve on the pump module. 3. Use the cap end to open the drain cock on the flow (upper) manifold. 7 close remove 8 5 fill the system 6 close 7 open connect 8 9 open 5. Fill the system via the boiler filling loop and run water through until the flow from the drain hose is free from air bubbles. 6. Close the boiler filling loop and drain cock. 7. Shut the flow isolation valve and open the return valve. 8. Remove the hose from the upper drain cock and connect it to the return (lower) drain cock. 9. Open the drain cock on the return (lower) manifold. 10. Repeat steps 5 and 6. 11 open 13 14 set to 0.5 bar 12 fit control valve 11. Open the flow isolation valve. 12. Fit the water control valve temperature adjustment head and adjust to minimum. 13. Fix the temperature phial and capillary tube to the pipe work on the underfloor heating side of the pump, using aluminium saddle piece and cable tie provided. 15. Repeat steps 1 to 12 at each manifold. Note: The system cold working pressure is 1.0 bar. When the system pressure has been set, isolate the filling loop and disconnect in accordance with water authority regulations. 14. The differential bypass valve should be set to 0.5 bar.
4.2 Setting flow rates and Commissioning Before starting check that: 1. The heating and hot water system is fully operational and the boiler has been commissioned. 2. Screed floors have been left to thoroughly dry out. The drying process depends on screed type and thickness, (please refer to BS8204), but allow a minimum of four weeks. The floor heating should not be used to accelerate the drying process. 3. All underfloor zones served by the manifold have been filled, flushed and pressure tested. See Section 2.2. 4. The boiler and primary flow and return have been filled, flushed, cleansed and vented. See Section 4.1. 5. All electrical work associated with the heating system is complete and actuator heads are fitted. (where appropriate see A3 Manifold & Zone Information for specific information) 6. The system static pressure is set at 1 bar when cold or approximately 1.5 bar when hot. 7. The main manifold isolating valves are open. 8. All pipes entering the manifold assembly have been clearly marked with their zone number and name as detailed on the system design. 9. All actuators cables have been similarly labelled. 4.2 Commissioning set to speed 3 1 Dining Room Zone 3 To set the flow rates 1. Set the floor heating pump to speed 3 and start by turning up all the room thermostats. Make sure all zones are flowing. When a zone is open the blue indicator on top of the actuator head stands proud. There is a 3 minute delay before the actuators open fully. 2. Each zone has a specific flow rate which is detailed on the A3 Manifold & Zone Information. Starting with the zone needing the least flow, lift the red locking collar around the flow gauge, reverse it and use it to turn the black nut. Turn the nut anti-clockwise to increase the flow, or clockwise to decrease the flow. Following the flushing procedure the valves are likely to be fully open. Replace the red locking collar. Note: Flow rates detailed on the A3 Manifold and Zone Information sheet are a minimum. The flow setting should be set as close to this level as possible or slightly above. Increasing the flow to one zone may slightly decrease the flow to the others and small adjustments may be necessary. 3. Record the flow rates on the labels provided. It is essential that actuators and zone pipes are correctly labelled. The room thermostat must control the actuator on the pipe serving that zone. 3 Zone: Flow Rate l/ m : Enter flow rate on labels
To set the temperature 4.2 Commissioning 5.1 EnergyMaster cylinder 4.2 Commissioning 1. Turn all the room thermostats up to a high temperature. This will open all the zone isolating actuator valves. 5.1 Commissioning the EnergyMaster Cylinder (where fitted) System Settings 2 Set cylinder thermostat to 3 Set floor heating 4 Set cylinder shunt 5 65 70 C maximum. pumps to speed 3 pump to speed 2 1. Boiler Thermostat set to a higher temperature than the cylinder thermostat (minimum 75 C). Ensure the boiler output rating is set to maximum. If resetting is necessary, please refer to manufacturer s instructions. Note: When the system has been running for at least 60 minutes, the temperature difference between the flow and return pipework at the boiler should be approximately 11 C. If it is much higher than this, check that the boiler pump is set to speed 3, (if using a system boiler the pump will be inside the boiler and may not be adjustable). If it remains high, please call Nu-Heat Customer Support for advice. Commissioning 2 adjust direct mounted pump remote mounted pump 2. Adjust the floor heating water temperature control valves (found either next to the manifold, or on to the Remote Mounted Pump Module) to give the correct flow temperature as detailed on the A3 Manifold & Zone Information. This temperature can be verified on the gauge on the flow (top) rail of the 2. Set the cylinder thermostat to 65 C. This can be increased to a maximum of 70 C if necessary providing the boiler thermostat is at least 10 C higher. Set boiler pump to speed 3 The system must now be thoroughly checked in accordance with the Commissioning Checklist and Warranty Application form in the Commissioning Pack. This must be fully completed during the commissioning process and returned to Nu-Heat for registration. No warranty can be issued without the return of the completed Commissioning Checklist to Nu-Heat. manifold(s). Final adjustments may be necessary when the system is up to operating temperature. Note: For screed floors set the water temperature at minimum for the first three days, and then only increased by 5 on each subsequent day. 3. set the cylinder shunt pump to speed 3. 4. Set the boiler pump to speed 3. Installing the inhibitor As soon as the commissioning is completed an inhibitor must be introduced into the heating system. For continued long-term protection the system inhibitor levels should be checked annually. 2 adjust verify 2
6.1 Aquastar hot water loop The Aquastar2 instant hot water loop (or for larger systems, Aquastar3) may be used with many modern hot water cylinders to give hot water at the taps without delay. The hot water loop will remain hot as dictated by the timer settings. Hot water drawn outside of the set times will take time to flow hot, as if the hot water loop were not present. The Aquastar hot water loop provides the ideal basis for the connection of towel rails throughout the house as very little extra plumbing is required. Heat for the towel rails is drawn from the existing heat reservoir in the hot water cylinder, usually without the need to bring on the boiler. Notes: The Aquastar hot water loop is only suitable for mains pressure hot water cylinders. Check that the installation of a pumped hot water loop is consistent with local water bye-laws. Appearance of pumps may vary Non-return valve Pump Timeclock 6.1 Aquastar hot water loop As the towel rails are heated by mains water they must be non-ferrous to prevent corrosion. The total output from all towel rails connected to the hot water loop must not exceed 5000 watts. Please contact Nu-Heat if the total output will be greater. The temperature of the loop, and therefore of the towel rails, is thermostatically controlled to prevent scalding. On the side of the Aquastar2 circulating pump there is a thermostat or, on larger systems, there is a separate thermostat mounted on a nearby pipe. The return temperature of the hot water loop should be 50 C or greater in accordance with BS6700 and the HSC s Legionnaires disease: The control of legionella bacteria in water systems Approved Code of Practice and Guidance. If the temperature of circulation necessary to achieve this poses a significant risk of scalding then the temperature should be blended as close to the outlet as possible. 6.2 Planning and installing the loop Bathroom 1 Flush/drain Larger systems have Aquastar components supplied as separate items Discharge Expansion vessel The hot water loop should be run throughout the year. If it is inactive for more than a week there is a risk of bacterial growth, such as legionella. Bathroom 2 Pipe stat out For cylinder connection details refer to cylinder manufacturer return Pump Outlet balancing valves Radiator lockshield valves Bathroom 3 Kitchen Utility Non-return valve (may be part of pump) Flush/ drain Discharge Ball valves for loop balancing Careful thought should be given to the layout of the hot water loop and the fittings used on it. Flow pipework to bathrooms should be sized according to the hot water requirements of the household. Typically a small to medium sized installation will require 22mm flow pipework, a large installation may require 28mm or greater. 15mm pipe may be used for the last 2 metres where the pipe connects to the Aquastar2 pump (22mm for Aquastar3). Individual hot water outlets should be fitted with flow-limiting valves to prevent unnecessarily high water flow rates affecting the water pressure at critical points such as shower units. It is recommended that only lockshield valves are used with towel rails on a secondary hot water loop. Towel rails should not be isolated from the loop for any significant amount of time (more than a few days) or there is a risk of bacterial growth, such as legionella. Fit a balancing valve or towel rail at the farthest end of each loop. If bathrooms are to be connected to the hot water loop in parallel, balancing valves must be fitted on each leg so that balancing between bathrooms can be effective (see illustration). The hot water flow and return pipes should be insulated to prevent unwanted heatloss. This is particularly important where hot pipes run alongside the supply pipes to cold tap.
7.1 Problem solving underfloor heating 7.1 Problem solving Problem: Solution: Problem: Solution: Electrical components not operating Please refer to the Electrical Checklist to confirm the system and system components are wired correctly. If the component still fails to work it should be replaced. No flow rate at the Optiflo manifold Is there flow to any zone? No Check the pump and replace if faulty. Yes Are the actuators open? No Check the actuator lead is properly connected to the Optiflo wiring board. The air vent can be removed to check impeller rotation Yes The ufh tubes may be air-locked fill and flush the system again. The ufh tubes may be wrongly connected, ie, flow to flow and return to return with no circulation reconnect correctly. The ufh tube may be kinked investigate and correct. The blue button will pop up when open Problem: Low flow rate on the Optiflo manifold Solution: Check the pump is set to speed 3 and is circulating in the correct direction as in Section 1.5. Check the ufh tube for air locks, wrong connections or kinks as above. Following adjustment, are the design flow rates correct for the majority of zones? No Please contact Nu-Heat Technical. Yes Turn off all the zones, turn on one low flow zone. Can the correct flow be set? No The ufh tube is air locked, kinked or wrongly connected. The pump should be set to speed 3 Yes Try each zone singularly in turn and re-balance all the flow rates. If all the design flow rates are still unachievable consult Nu-Heat Technical. Problem: Solution: Low water temperatures on the Optiflo manifold After more than 48 hours of system operation by adjusting the water temperature control valve is the design flow temperature achieved? No Check the boiler is set to maximum. Check the Energymaster cylinder (if fitted) thermostat is set to 65 70 C. Check that the boiler auto bypass valve is set correctly to 0.4 bar. If the design flow temperature is not achieved consult your installer as the boiler is not providing sufficient heat to the underfloor heating system. Direct water temperature control valve Yes If there is more than 15 C difference between the design flow temperature and the return temperature allow more time for warm up and then increase the flow rates. Remote water temperature control valve
7.1 Problem solving underfloor heating, continued Problem: Solution: No heat to one zone Is hot water flowing to the zone? No Check the electrics, flow rates and flow temperatures as detailed above. Yes The zone actuator heads are fitted to the wrong zones. To check connections are correct: Turn all room thermostats down to 5 C, Zone: Flow Rate l/ m : Actuator heads must be correctly labelled 7.1 Problem solving Check one zone at a time (all other zones must be off), Turn the thermostat in the zone up high, If another zone is getting warm it indicates that the actuator controlled by the thermostat is probably fitted to the wrong zone valve, Continue to test all other zones and move actuators to their correct positions, Re-label actuator heads when you are happy that they are correctly connected. Problem: Low heat to one/several zones Solution: Is the flow rate and temperature correct? No Check the flow rates and flow temperatures as detailed above. 12:00 Yes Increase the flow rate to the maximum possible (see diagram below). If the room(s) have a high heat loss, ie. a lot of external walls and windows, the timeclock settings may be insufficient to allow for extended warm-up times. Set the timeclock to turn on earlier. Adjust timeclock settings or programmable thermostat If the problem persists increase the flow temperature (see diagram below); do this gradually as excessive temperatures may damage natural flooring and tiles. If problems are still experienced after following the above instructions, please contact Nu-Heat Technical. Manifold components Flow gauges (see A3 manifold & zone information) Flow temperature gauge Flow adjustment Manual air vent Filling/drain off valve Floor heating pump (direct mounted) Main isolating valve (return flow is behind) Actuators Pressure gauge Temperature blending valve Filling/drain off valve Return temperature gauge