Uponor one pack easy install guide by Uponor UK

Professional underfloor heating ! Install a complete underfloor heating system, up to 75m2 6 easy to follow installation steps using one pack The simple route to a professional solution.

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Professional underfloor heating ! Things to consider... Heat Outputs

Floor Coverings

The maximum output from an underfloor heating system is often stated at 70 W/m2 for timber floors and 100 W/m2 for screed floors.

Most floor coverings can be laid on UFH systems.

In buildings that meet current Building Regulations, it is unusual to require more than 70W/m2 heat output, based on a 20OC internal design temperature. In older buildings it is important to consider greater heat losses. Conservatories, rooms with high ceilings and areas that are poorly insulated may require supplementary heating. As with any home, the more effective insulation you have, the more efficient heating system you will gain. When designing conventional heating systems it is necessary to know the required heat output to determine the size of the heat emitter. When designing an underfloor heating system, the heat emitter is the floor area and is fixed. The heat output achieved is a direct relationship between the difference in floor surface temperature and room air temperature. The floor construction, floor covering material, pipe size, pipe spacing (or pipe centres), and the temperature of water circulating through the UFH pipes are major factors that determine the floor surface temperature.

For optimum performance, masonry coverings; ceramic floor tiles, slate, stone, marble, etc. are chosen as this offers minimum thermal resistance. Wooden floors and carpets may also be used. Uponor recommend a maximum combined thermal resistance of 0.15m2K/W is not exceeded for floor coverings. Carpet underlays should be less than 1.0 TOG and should be suitable for use with underfloor heating, while carpets should have a maximum 1.5 TOG value. Thick felts, thick underlay (TOG value greater than 1), and cork should be avoided. More detailed information regarding floor coverings can be found in the User Instructions chapter, page 36.

Insulation In older buildings it is important to consider greater heat losses. Conservatories, rooms with high ceilings and areas that are poorly insulated may require supplementary heating. As with any home, the more effective insulation you have, the more efficient heating system you will gain. NOTE:

Consult your flooring supplier for additional considerations such as maximum temperature limits, wood drying conditions, special glues, etc.

NOTE:

Refer to building regulations for further information about insulation.

Visit www.one-pack.co.uk for step by step installation videoâ&#x20AC;&#x2122;s 2

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Contents

Step 1

Preparation

Step 2

Laying Loops

Step 3

Connections

Step 4

Controls

Step 5

Filling & Pressure

Step 6

System Start Up

FAQ

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Pack Content & Components Item codes

Item 16mm PEX pipe 80m coil(s) Single loop manifold Single loop manifold fixing bracket Actuator(s) Edge strip Pipe fixing clips 16mm 3/4” manifold connectors Pipe cutter Pipe bend supports Manifold 2-5 port 1” isolation valves Compact control pack Manifold 2-5 port complete with compact control pack Wired zone controller Digital Wired programmable thermostat(s) Radio zone controller Digital radio thermostat 

Item(s) come with every pack



1058856 1002197 1002278 1002053 1000080 1002297 1057441 1001369 1009004 1002201-04 1059132 1059842 1059843-46 1000534 1048012 1045564 1000502

1 Zone, 1 loop 0-15m2

Zones above 15m2

        



     

            

Item(s) option depending on your selection

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80m coils of PEX Pipe 16mm - 1058856

Single Loop Control Set

Diffusion resistant PEX pipe with four layer technology including oxygen barrier. For use with underfloor heating applications only. Maximum operating limits: 6 bar, 70oc

Wired Programmable Thermostat - 1048012 Used for creating a time temperature schedule for the users needs. Has a large LCD which displays the ambient and setpoint temperature. Contains the unique patented “Auto-Balance Technology” proven to increase energy savings by 12%.

Uponor Compact Control Pack V5, Single Loop TM Manifold and Wall Mounting Brackets. Components boxed separately and require on-site assembly.

Wired Zone Controller - 1000534 12 Channel controller for use with the wired programmable thermostat. Powers thermostats and corresponding actuators connected to the system. Includes features such as “auto-linking” and “fallback”.

TM Manifold - 1002197 CCP V5 - 1059842 Manifold Fixing Brackets - 1002278

Manifold 2-5 Port c/w Compact Control Pack - 1059843-46 Pre-assembled manifold and CCP for use with systems requiring water temperature control. Supplied ready for installation, “Box to Wall”.

Radio Zone Controller and Interface - 1045564 12 Channel controller c/w interface for programming and scheduling. Contains the unique patented “Auto-Balance Technology” proven to increase energy savings by 12%. Radio Digital Thermostat - 1000502 Temperature control range from +5°C to +35°C. Digital display allows user to view ambient and set point temperature.

Pipe Cutter - 1001369 Actuator - 1002053

Plastic pipe cutter for 16mm PEX Pipe.

Connected to the return ports of the manifold providing on/off control of flow into the UFH loops. Includes a visual indicator for open and close position.

Pipe Bend Supports - 1009233 Used for creating a stable 90o bend when connecting the pipes from the mainifold to the floor.

Edge Strip - 1000080 For use on solid screed floors as perimeter wall insulation, to reduce thermal bridging. Made of polyethylene with self adhesive backing and PE skirt providing tight seal between edge strip and insulation.

Manifold 2-5 port - 1002201 - 04 Manifold includes topmeters for flow regulation and measurement. Supplied pre-mounted on chrome plated brackets with vibration spacers. Also includes fill and drain points and 1” BSP primary connections.

Kombi Klip - 1002297 Used for fixing 16-20mm underfloor heating pipe to most types of insulation. The barb length is 33mm and requires a minimum of 35mm insulation depth. For use with Uponor Kombi gun 1002295.

Eurocone Compression adaptors (PEX Pipe) - 1057441 Made of plated brass ¾”FT Eurocone thread for connection to ¾”MT outlets of TM Manifolds.

Isolation Valve - 1059132 1” isolation valves used for connection/ isolation of the primary system to the plain UFH manifold.

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Planning Your Installation

�� Before laying any pipe, time should be spent planning a route from the manifold location to the respective zones. Once you have a clear idea of the installation, you can begin to lay the pipe.

Manifold Location

��

During the pack selection process, a central and accesible location is specified for the manifold, and this position must not change during installation. In the example shown to the right, the manifold is located in the storage cupboard under the stairs. As the designer has defined four zones, the manifold has four ports. In properties with larger rooms, 2 or more loops may be required for a heated zone.

4 ��

3��

��

1 2 3 4

��

Loop Allocation Also during the pack selection process a “Pack Selection Table” will have been filled in, either on the computer or on paper. This form is now required as a guide to your installation. The Pack Selection Table identifies how many loops of pipe are required for each heated zone. Below is an example drawing showing the loop and zone allocation from the Pack Selection Table.

��

1 �� 2 ��

�� utility kitchen/dining

Plan to install one zone at a time, in a methodical order, as pipework must not cross over. Utilise the ports of your manifold sequencially, from the first to last or vice versa. Allow room for your pipe to ‘run’ to zones and ‘return’ to the manifold.

W/C

st.

TIP:

Lay pipe 100mm from walls, so not to damage pipes when installing your floor convering.

TIP:

Lay feeds to heated zones at 50mm centres between flow and return pipes. Leave space for feeds routed through other areas.

st. hall

IMPORTANT! Pipes must not cross over each other. living room hall

�� 6

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Solid Floor Installation INFO:

Floor must be level, and swept clean of dust and debris before starting your installation.

Insulation NOTE:

Edge Strip Fix the edge insulation continuously around all internal and external wall edges, using the adhesive backing. When installed correctly the PE-skirt will face out from the wall and the embossed â&#x20AC;&#x2DC;Uponorâ&#x20AC;&#x2122; will be legible.

Insulation must conform to Building Regulations.

Lay the floor insulation over the entire floor area, butting up to the edge strip, ensuring the PE skirt overlaps. Tape the PE skirt onto the floor insulation. The Klips will grip to the insulation to secure pipe in position. A protective membrane may be required to protect the insulation from chemicals in the screed. Please consult your screed supplier for guidance. If a protective membrane is required, lay this immediately over the insulation. You will lay pipe on top of the membrane and the Klips will pierce through. TIP:

If you do not require a protective membrane, you can prevent screed from slipping between sections of insulations by taping at the seams.

Planning Your Installation When installing underfloor heating on a solid floor, it is imperative the pipes do not cross over each other. Before laying any pipe, time should be spent planning a route from the manifold location to the respective zones. Once you have a clear idea of the installation, you can begin to lay the pipe.

utility kitchen/dining

W/C

Each loop must be installed without any joints in the floor. To assist with installation, Uponor pipe is marked every metre. Keep reference of how much pipe has been laid whilst installing over the intended floor area. This will help ensure you return to the manifold with sufficient pipe.

st. st.

If required, lay more than one loop to a zone.

hall

Laying Loops IMPORTANT! A loop is one continuous run of pipe from the flow port to a return port of a manifold. Never join two coils in attempt to create one longer loop of pipe. Start with the first or last coil to be run from the manifold. In the case of the example, the installer could begin with either the living room or the kitchen/dining, We will start with the living room. Take your first coil and temporarily secure the end of the pipe at the manifold by lodging it behind.

living room hall

Pipe should be laid 100mm from external and internal walls until you reach the zone you have planned to install first.

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Once you reach the entry point for this zone, pipe direction is to the coldest area of the room first, for example, along external walls and under windows.

utility kitchen/dining

Lay the pipe as you walk, securing every half a metre with a Klip, which is pushed over the pipe and into the insulation. TIP:

W/C

st.

The Uponor Kombi Gun; A quick and simple method for fixing Uponor MLC and PEX pipe to all common UK underfloor heating insulation boards. Item number: 1002295

st. hall

Travel to the furthest point of the room and make a 180O turn as shown in the drawing below. The pipe needs to ‘meander’ back and fourth across the floor at 200mm centres on it’s return to the entry point, then follow the same route back to the manifold.

living room

On returning back to the manifold temporarilly secure the pipework; ready to make connections.

hall

Once the first loop is complete work through the others one after another. The example started with a loop for the living room zone. The next zone in the example will be for the hall & WC, followed by the utility and finaly the kitchen.

Insulating Congested Pipe In order to prevent the floor from overheating directly below the manifold or through doorways, or any areas where pipes may be closer together, we would advise insulating the pipe, especially if they are not used to heat the room through which they pass.

utility kitchen/dining

50m of protective conduit suitable for 16mm pipe, Item number: 1012860

W/C

TIP:

Feed pipes can be taken directly through partition walls and into their respective zones to reduce congestion.

NOTE:

Ensure all pipe remains below the screed floor finished level at all points. Where pipe passes through walls, ensure the pipe is sleeved to allow for expansion.

st. st. hall

living room

SCREED: hall

Your floor area is now ready to be filled and pressure tested. Once filled and tested, lay screed as soon as possible to protect the pipe. Avoid unnecessary foot traffic on the floor area until screed is completely dry. Consult you screed supplier for drying times.

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First Fix Plumbing & Wiring with Water Temperature Control Every underfloor heating installation will require a hot water feed from the boiler to the manifold. The Heating Pack is designed to have the primary pipe work from your boiler enter the manifold assembly on the bottom left. Various components in the one pack will need connecting to your existing electrics.

Adding to an existing system.

First Fix Wiring

An ‘S plan’ plumbing arrangement is required to run an underfloor heating system along side your existing heating and hot water circuits. An S plan arrangement will allow UFH, radiator and hot water circuits to be controlled independently, each by two port motorised* zone valves. If a mid position (Y plan) arrangement is present on an existing system that you wish to add to, Uponor advise altering the arrangement to S plan, removing the mid position valve and inserting a two port motorised zone valve to isolate the radiator circuit and a second two port motorised zone to isolate the hot water cylinder. The Uponor One Pack provides a third zone valve for the underfloor heating system.

A 230V fused spur will be allocated to the UFH system at or near the manifold location, to supply all of the electrical components within. CAUTION: All wiring must be completed by a competant person and must comply with current IEE regulations.

Digital Wired Thermostats A 2 core plus earth cable with a minimum cable size of 0.5mm and a maximum cable size of 1mm is required for use with the digital wired thermostats.

NOTE: Two port zone valve supplied by others if required.

Position the thermostats in each zone, out of direct sunlight and away from other heat sources or draughts.

First Fix Plumbing

Each digital wired thermostat needs be wired back to the zone controller, which should be positioned above the manifold.

The zone valve should be fitted on the pipe work between the boiler (on the positive side of the primary pump) before the manifold.

Optional floor sensor, for digital wired thermostat, is supplied c/w 4m length of 2-core cable.

We suggest the following sizes and pump settings: Manifold Size

MLCP

PEX

Copper

Pump Setting*

1 circuit

16mm

15mm

turn clockwise to 3 o’clock position

2 circuit

16mm

15mm

turn clockwise to 3 o’clock position

3 circuit

16mm

15mm

turn clockwise to 3 o’clock position

4 circuit

20mm

15mm

turn to furthest clockwise position/4 o’clock

5 circuit

20mm

22mm

turn to furthest clockwise position/4 o’clock

*Pump settings are for guidance purposes only, finer adjustments can be made for a more accurate and efficient flow rate.

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First Fix Plumbing & Wiring without Water Temperature Control

Adding to an existing system.

First Fix Wiring

Digital Wired Thermostats A 2 core plus earth cable with a minimum cable size of 0.5mm and a maximum cable size of 1mm is required for use with the digital wired thermostats.

NOTE: Two port zone valve supplied by others if required.

Position the thermostats in each zone, out of direct sunlight and away from other heat sources or draughts.

First Fix Plumbing

Each digital wired thermostat needs be wired back to the zone controller, which should be positioned above the manifold.

The zone valve should be fitted on the pipe work between the boiler (on the positive side of the primary pump) before the manifold.

Optional floor sensor, for digital wired thermostat, is supplied c/w 4m length of 2-core cable.

We suggest the following sizes and pump settings: Manifold Size

MLCP

PEX

Copper

Pump Setting*

1 circuit

16mm

15mm

turn clockwise to 3 o’clock position

2 circuit

16mm

15mm

turn clockwise to 3 o’clock position

3 circuit

16mm

15mm

turn clockwise to 3 o’clock position

4 circuit

20mm

15mm

turn to furthest clockwise position/4 o’clock

5 circuit

20mm

22mm

turn to furthest clockwise position/4 o’clock

*Pump settings are for guidance purposes only, finer adjustments can be made for a more accurate and efficient flow rate.

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Compact Control Pack V5 - Single Loop Systems

Single Loop Systems The Uponor Compact Control Pack is for controlling the flow and temperature of water around your UFH System. For 15m2 single zone, only a single loop is required. The manifold, compact control pack and brackets are supplied separately and require on-site assembly.

Boiler Returns UFH Flow

Pump Flow

Boiler Flow UFH Returns

Assembling the Manifold and Pump Connection Components

• •

Remove and Discard Manifold Securing Pipe Nipples

•

Connect the other end of the manifold to the 1”MI x Swivel nut adaptor.

•

Connect the High Limit Thermostat, Pump connection and fill and drain assembly to the above.

•

Now connect the pump to the Flow assembly with the pump flow direction towards the flow manifold section on the top of the Pump.

Connect one end of the Manifold (with Flow Indicator) to the Capped Lock shield Valve

•

Connect one end of the Blue Capped manifold to the Thermostatic Headed Mixing Valve.

•

Connect the other end of the manifold to the 1”MI x Swivel nut adaptor.

•

Connect the Pump isolating valve, Pump connection and fill and drain assembly to the above.

•

Now connect the pump to the Blue Capped Manifold assembly.

Assembling of the Manifold and Pump Wall Brackets. Place the wall brackets,1 behind the space between the manifold and large swivel connecting nuts, the other to the side of the fill and drain valves. Now place the bracket front securing straps into position then secure the Manifold assembly with the fixing screws. (The Brackets are designed to be a tight fit) The whole unit can now be positioned, marked then secured to the wall, ready for the pipe connections. The base of the manifold should be a minimum of 300mm from the floor to allow room for the pipe to bend up to the manifold outlets. Space must also be available to make the primary pipe work connections on the left as shown.

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Compact Control Pack V5 - Multi Loop Systems The Uponor Compact Control Pack is for controlling the flow and temperature of water around your UFH System. There are only a few connections to be made.

Boiler Returns

UFH Flow

Boiler Flow

Pump Flow

UFH Returns

The Uponor Compact Control Pack is for controlling the flow and temperature of water around your UFH System.

Single and Multiple Loop Systems 1. First, fit the pipe sensor within the 90 degree elbow as shown 2. Tighten the grub screw with the small Allen key included. Next fit the thermostatic head onto the valve body. 1.

Tighten by turning the metal ring clockwise until it is hand tight. Using appropriate wall plugs and fixing screws, mount the manifold on the wall. The base of the manifold should be a minimum of 300mm from the floor to allow room for the pipe to bend up to the manifold outlets. Space must also be available to make the primary pipe work connections on the left as shown.

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Manifold without water temperature control Plain manifold installation requiring the primary water to be supplied at the correct temperature for the underfloor heating system. Supplied with 1â&#x20AC;? isolation ball valves for primary side connection. Also include fill and drain points with conversion adaptors.

Boiler Flow UFH Flow

Boiler Return UFH Return

Connections at the Manifold 1. Before pushing the pipe behind the manifold, carefully bend the pipe to prevent it being damaged.

2. Line the pipe end up to the threaded port on the manifold.

3. Cut the pipe end square, level with the bottom of the thread, using plastic pipe cutters, as shown.

4. Push the nut and olive onto the end of the pipe. Then push the insert fully into the end of the pipe end in order to get a secure joint.

5. Slide both the ring and nut onto the manifold port and connect to the manifold outlet.

6. Now tighten the adaptor fitting onto the manifold, using an appropriate spanner.

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System Wiring - 12v Hard Wired option Digital programmable thermostats to zone controller

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Compact control

System Wiring - Connection of Radio/Wired Controller to Water Temperature Control 1.

Relay1 Relay2

Wiring Box

Relay1 Relay2

Wired / Radio Zone Controller

N L

Wiring Box

N L

Wired / Radio Zone Controller

White 230V Supply From Fused Spur

230V Supply From Fused Spur

Step 1

Step 2

N L E

Step 6

N L E

Safety High Limit Thermostat

N L E

Relay1 Relay2

Wiring Box

N L

Relay1 Relay2

Wired / Radio Zone Controller

Wiring Box

Relay1 Relay2

Wired / Radio Zone Controller

N L

Wiring Box

Wired / Radio Zone Controller

N L

White 230V Supply From Fused Spur

Step 3b

N L E

Relay1 Relay2

N L

Wiring Box

Wired / Radio Zone Controller

Step 8

N L E

N L

Safety High Limit Thermostat

N L E

Wired / Radio Zone Controller

White

230V Supply From Fused Spur

Step 3a

Relay1 Relay2

N L

Wired / Radio Zone Controller

Safety High Limit Thermostat

White Wiring Box

230V Supply From Fused Spur 30 20

N L E

Safety High Limit Thermostat

C째

60 70

10 0

White 230V Supply From Fused Spur

Step 4

White

230V Supply From Fused Spur

N L E

Step 5

Step 10

Safety High Limit Thermostat

N L E

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U hea

mpact control

System Wiring - Connection of Radio/Wired Controller to Water Temperature Control 7.

Relay1 Relay2

Wired / Radio Zone Controller

N L

Wiring Box

N L

Relay1 Relay2

Wired / Radio Zone Controller

Wiring Box

Wired / Radio Zone Controller

N L

White

Step 7

Safety High Limit Thermostat

N L E

Relay1 Relay2

Wired / Radio Zone Controller

Wiring Box

Wired / Radio Zone Controller

N L

White

10.

Wired / Radio Zone Controller

White

230V Supply From Fused Spur 30

N L E

White

Safety High Limit Thermostat

Underfloor heating pump

C째

60 70

10 0

White Underfloor Heating Pump

230V Supply From Fused Spur

Step 8

N L E

Safety High Limit Thermostat

N L E

White 2

230V Supply From Fused Spur

Step 6

N L

White

230V Supply From Fused Spur

N L E

Step 9

Safety High Limit Thermostat

N L E

12.

11.

Relay1 Relay2

N L

Relay1 Relay2

Wired / Radio Zone Controller

N L

Wired / Radio Zone Controller

Common and switch live for boiler enable *CONTACT BOILER MANUFACTURER IF UNSURE WHERE TO CONNECT*

Safety High Limit Thermostat

White Wiring Box

30 20

High Limit mostat

Wiring Box

C째

60 70

10 0

White

230V Supply From Fused Spur

Step 10

White

230V Supply From Fused Spur

N L E

Safety High Limit Thermostat

Underfloor heating pump

Zone valve (by others)

Step 11

N L E

Safety High Limit Thermostat

Underfloor heating pump

Zone valve (by others)

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System Wiring - Radio/Wired Zone Controller without Water temperature Control 1.

3a.

3b.

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System Wiring - Radio Zone Controller with Water Temperature Control

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System Wiring - Radio Zone Controller without Water Temperature Control

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System Wiring - Wired Zone Controller with Water Temperature Control

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System Wiring - Wired Zone Controller without Water Temperature Control

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Wired Digital Programmable Thermostat set up

1. Start up screen.

2. Display screen. Press and hold OK until screen 3 appears.

3. Press OK once to enter clock menu.

4. Adjust year using + or - , confirm by press ing OK.

5. Select month 01 = Jan, confirm by pressing OK.

6. Select day of month and confirm by pressing OK.

7. Choose between 24hr or 12hr time clock, confirm by pressing OK.

8. Adjust to correct time confirm by pressing OK.

9. Confirm automatic summer winter time, change by pressing OK.

10. Enter programming menu by pressing OK.

11. Select programming ON by pressing OK.

12. Select schedule group. 5/2, 6/1 or 7 using + or -. Confirm OK.

13. Press the + button until you reach the desired time for comfort operation.

14. Example shows 6am as the chosen comfort event. Press OK to put the person in the house.

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15. Example shows 9am as the next chosen ECO event. Press OK to take the person outside of the house.

16. Example shows 4pm as the next comfort event. Press OK to put the person inside the house.

17. Example shows 10pm as the next ECO event. Press OK to take the person outside of the house

18. Press the + button until 23:59. Leave until screen 19 appears.

19. Repeat process for days 6 & 7.

20. Press the + button once to scroll to next menu.

21. Enter MOD menu by pressing OK.

22. Select RT (room thermostat) using the - & + button and press OK. For further information on different modes please refer to section 9.5 page 28 of the Wired System operation and installation manual.

23. Enter BAL menu by pressing OK.

24. Select AB and press OK.

25. Press OK to enter comfort and ECO temperature settings.

26. Person inside house indicates comfort. Adjust value to suit using + & -. Press OK to accept.

Please see chapter 9 of the wired manual for more detailed information on thermostat settings. Alternatively please visit www.uponoruk.mobi 27. Person outside the house indicates ECO. Adjust value and press OK to accept.

28. Press and hold OK to exit back to main screen.

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Digital Radio Thermostat registration Register Room Thermostats An example of registering a thermostat: one thermostat controls two actuators that connect channels 02 and 03. 1. Push the Test button. The Test button LED lights up

2. Push channel button 02. 3. Push channel button 03. The LEDs of channels 02 and 03 will flash

4. Press and hold the (+) and (-) buttons for 3 seconds. The T-75 Thermostat will display CNF for configuration mode. 5. Press and hold the (+) and (-) buttons for 1 second. 6. LEDs will flash and turn solid, indicating a successful link. Repeat the same sequence for all thermostats. The Test LED switches off

LED

LED Status LED on LED flash LED off

Cancelling the Registration of a Channel 1. Press the Test button. The Test and channel LEDs with registered thermostats light up . 2. To cancel, press the channel button for 10 seconds.

3 seconds

5 seconds

The LED of the cancelled channel flashes seconds, then switches off .

for two

3. Press the Test button to exit registration mode. The Test LED switches off

Caution: To register a different thermostat to a channel, cancel the registration of the existing thermostat prior to linking to new thermostats. Then repeat the steps as outlined in the Register Room Thermostats section on this page.

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Radio Zone Interface Setup 1.

11. 20/01/2009 12:30

System MonTueWedThuFriSatSun ECO Night & Day

Language English Svenska / Swedish Dansk / Danish

Set Date/Time

12.

Room List All 1.01 Therm 1.02 Therm

13.

Rooms Room Name Min/Max Temperature Apply ECO Profile

12 : 00 01 Oct 2012

Autobalance Instalation Balancing Active Inactive

14.

Settings Rooms Edit ECO Profiles System Parameters

Main Menu Information Holiday Mode Settings

15.

Main Menu Information Holiday Mode Settings

Settings Rooms Edit ECO Profiles System Parameters

Rooms Room Name Min/Max Temperature Apply ECO Profile

Room List All 1.01 Therm 1.02 Therm

Controller 1 MonTueWedThuFriSatSun ECO Off

10.

Use down arrow to put marker against each day.

Hold down arrow untill ECO profile list appears.

ECO Profiles List ECO Off ECO All ECO Night & Day

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Filling & Pressure testing Filling Prior to filling the system check each connection on the manifold and Compact Control Pack is tight. There is an integral fill/vent valve above and below the pump. Two hose unions are required to connect onto the 3/4” thread.

• Ensure all electrical supplies are switched off. • Remove the fill port caps and connect a hose union to each.

• Fit a hose to the lower manifold hose union and run the other end of the hose to a suitable drain point.

• Connect a hose to the upper manifold hose union and connect the other end of the hose to a mains water tap.

• Individual loops need to be purged of air in turn. This is • The integral valves in both end caps must be opened to fill the system. Use the square key in the cap to open the fill port valves.

• Ensure the thermostatic control valve and lockshield valve are CLOSED and all connections are tight. To close the control valve on the V5 Compact Control Pack, first remove the white thermostatic head and use cap to close the valve.

achieved by opening the manual head (blue cap) on the lower manifold, then fully opening the corresponding topmeter on the upper manifold. To fully open the topmeter, remove the red locking ring and turn the topmeter 3 full turns from the closed position. Before attempting, read ‘TM manifold loop balancing procedure’ later in this chapter..

• Slowly turn on the water tap. As the first loop fills with water, air will discharge through the hose to the drain. Once the air stops and there is a steady flow of water, close both ports on the manifold. Repeat this procedure for all UFH loops on the manifold ensuring that the valves are closed on each loop after filling.

• Remove the white cap from the lockshield valve and close off with an Allen key.

• Fully close the valve on the elbow of the Compact Control Pack at the circulating pump inlet to ensure that water is forced around the UFH loops when filling and not short circuiting between the upper and lower manifold headers.

• Close the valves on the end caps and switch-off the mains water before disconnecting the hoses.

• Important: Please remember to open the valve at the circulating pump inlet. IMPORTANT! Remember to open the valve at the circulating pump inlet. IMPORTANT! Fill loops independantly of each other.

•

Close all underfloor heating loop flow and return valves on the manifold.

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Pressure testing A hydraulic pressure test must be carried out on all loops prior to laying the screed or covering with the chosen floor coverings. A hydraulic pressure test kit is available from Uponor (Item Number 1004057).

• Isolate the primary flow and return to the manifold. • Ensure that all flow and return valves to the UFH loops are open.

• Use the pressure gauge on the pressure test kit to monitor pressures.

• Connect a pressure pump to the hose union and open the valve on this end cap. Ensure the other hose union valve is closed.

• Uponor recommends that the system should remain under pressure whilst the floor is laid so that if any damage occurs to the pipe, the laying of the floor can be stopped and the damage repaired immediately. The floor should be laid immediately after the pressure test.

• Where there is a danger of freezing, suitable measures such as the use of glycol-based antifreeze should be taken, using the correct mixture of water and antifreeze solution. However, before start up, the glycol mixture must be thoroughly flushed out of the system and disposed of carefully.

• Pump up the pressure in the manifold to 2 x the operating pressure (minimum 4 bar, maximum 6 bar) for at least 1 hour. After an initial slight drop in pressure as the pipes expand, there should be no further drop in pressure. Check the pressure gauge during this period to ensure that the pressure remains constant under this period.

Use of Corrosion Inhibitors Uponor UFH pipes will not be:

• Adversely affected by corrosion inhibitors normally used in central heating systems.

• Adversely affected by accidental contact with linseed oil based sealing compounds, or soldering flux. However, the latter should not be used for making joints to the pipe.

• Affected by soft, hard or aggressive potable water. The pipe will not be attacked by any constituents of concrete, screeds, mortars, and is fully resistant to attack from micro organisms.

Settings

• The thermostatic head is set to the required water flow temperature for the underfloor heating system, typical settings as follows:

Screed floors: 40 – 45OC Wooden floors: 50 – 55OC

• The high limit thermostat does not need any adjustment. It is preset to 60OC.

• The lockshield valve needs to be opened so that it forces the majority of the water around the UFH system. The primary and secondary pump speeds, existing primary pressure and manifold size will affect how far open the lockshield valve needs to be opened, usually around 3 full turns from the closed position. The lockshied valve may need to be opened less/more depending on system performance.

• To make an adjustment first unscrew and remove the white cap. Use the included Allen Key to adjust the valve.

• To calibrate it is recommended that the lockshield valve is first fully closed and then opened until you see the thermometer continuously reading the same temperature as the setting on the injection valve head.

• Pump settings: Manifold Size

MLCP

PEX

Copper

Pump Setting*

1 circuit

16mm

15mm

turn clockwise to 3 o’clock position

2 circuit

16mm

15mm

turn clockwise to 3 o’clock position

3 circuit

16mm

15mm

turn clockwise to 3 o’clock position

4 circuit

20mm

15mm

turn to furthest clockwise position/4 o’clock

5 circuit

20mm

22mm

turn to furthest clockwise position/4 o’clock

*Pump settings are for guidance purposes only, finer adjustments can be made for a more accurate and efficient flow rate.

• Typical loop flow rates, for varying loop lengths and Floor output [W/m2] are shown on the table at end of this chapter.

• Adjust the circuit flow rates by adjusting the flow regulators (topmeters) -see following pages.

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System Start Up System Start-Up

General Commissioning

When the system has been connected to the heat source and all pumps, controls, valves and bypasses fitted, the system

• If removed, refit all thermal actuators. • With the electric power off, initially set all room thermostats

should be checked and started as follows.

• Where applicable, ensure that the screed has had sufficient time to cure in accordance with manufacturers instructions and relevant British Standards, typically between 21 – 28 days.

• Check and ensure all electrical controls are wired correctly and in accordance with the latest edition of IEE Wiring Regulations, or ETCI National Rules for Republic of Ireland.

• The system set-up and control arrangement should be checked to ensure correct operation.

• Check that the system is filled with water and fully vented of air and all isolating valves are fully open. Once this is complete, the pumps should be run for 5 minutes on the “Venting Function” setting and then a final check should be made to ensure that all air has been vented from the system.

• Check that the boiler is operating in accordance with the manufacturers instructions and set to run with a flow temperature at least 15oC higher than the UFH design flow temperature. (CCPV5 only)

• Ensure all flow meters are fully open and that auto balance has been activated.

5oC above current room temperature so that they call for heat.

• Set the water temperature control at the lowest possible setting (between 25 - 30oC).

• Switch on the UFH system and ensure UFH pumps are

running and all relevant valves are open. Remember that the thermal actuators take some time to operate and there will be a 2 – 4 minute wait before they are fully open.

• If the foregoing procedures have been completed

satisfactory, turn all room thermostats down and wait for the system to stop.

• When the system has stopped, turn up one room thermostat at a time and wait for the system to start. Then confirm that the correct circuit (loop) actuator(s) has opened for that particular room and immediately turn the room thermostat down again in that room.

• Wait until the system has stopped and then repeat the

process on a room by room basis, ensuring that every actuator is controlled by the correct thermostat and that each one switched the system on and off. This should also include the boiler being switched on and off, providing there are no other user circuits, e.g. radiators and/or hot water primary circuits, calling for heat.

• Run the system at the lowest possible setting for at least 3

days, before raising the water temperature to the maximum design temperature, which should be maintained for at least a further 4 days.

• Set the room thermostats to the required levels and programme the system controls to run as required.

• When running normally, the temperature difference between the manifold flow and return connections may be between 5-10oC.

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Fault Finding Initial checks of for the primary system If the water arriving at the manifold is either cold or below the design temperature, check: • the boiler is firing • the primary pump is fitted • the primary pump is working • the boiler is of adequate size • the primary pipework is sufficiently sized Fault finding - Electrical Problems In all cases where an electrical fault is reported it is always prudent to check the obvious before replacing components. • Is there an electrical supply? • Is it switched on? • Are there any fuses that may have blown and need replacing? • Are any components overloaded? • Is everything wired correctly? Under no circumstances replace a fuse with a higher rating than stated for that piece of equipment. The following flow chart is designed to aid the installer in electrical fault finding for the radio/wired zones. If a loop or loops fail to warm, when other zones are working correctly. General things to look for:

• Check that the corresponding manifold valves are open • Check that there is a demand from the corresponding room thermostat and/or the thermal actuator is open on demand.

• There may be an air lock in the loop, which will require

purging. Either shut down all other loops by closing the valves at the manifold or turn down all other room thermostats. This will concentrate all pump pressure to the problem loop and may shift the air blockage. If all else fails the loop can be flushed through with high-pressure water following the instructions detailed in Filling, Venting and Pressure Testing. If circulation is apparent but poor, it may be that the lockshield valve on the manifold requires adjustment.

If the system is too noisy. General things to look for: • There is no air in the system • That all pipes are firmly clipped in place and that the manifold brackets are tight. • That excessive pressure from another circulator in the system is not interfering (hence the importance of having a primary bypass). If the running costs are high. General things to look for: • That the UFH system is correctly electrically connected to the boiler to prevent short cycling and to ensure that the boiler is not running when it is not required. • That the room temperatures and thermostat settings are not too high (typical comfort temperatures are 20OC in living quarters and 18OC in bedrooms). • For any open windows or draughts. It is not unknown for windows to be opened in cold weather, as the internal comfort remains constant with thermostatic controls. • That the boiler is running correctly. Has it been serviced and/or commissioned by an approved engineer. • That the floor downward losses are high due to inadequate level of floor insulation. The system is losing pressure. General things to look for: • If the system is losing pressure either during testing and/ or after the system has been filled, but the flooring has not been laid, simple visual/manual checks around the manifold and along each loop of pipe should identify the problem area. • If there are no clear visual signs, each loop/circuit may require a separate pressure test to identify the exact location. • If the floor has been laid, identification of the fault can be traced through signs of a wet patch around the leak. Obviously to make the repair, the floor will have to be raised. In screed floors, excavate carefully in the centre of the wet patch.

• Any leaks on the manifold are generally due to the connection and any loose nuts and unions will require tightening.

Check the pump isolating valve on the V5 Compact Control Pack is open. If a room fails to warm. General things to look for: • That the room thermostat fitted is calling for heat and that the valve has opened using the visual window on the actuator. • That the room thermostat is connected to and communicating to the correct actuator(s). • That the room thermostats are not operating in temperature set-back mode. • That the primary flow and return connections are installed correctly and not crossed over at the UFH manifold. • That the primary water temperature is not too low. This needs to be at least 15OC higher than the UFH system water temperature when using CCPV5. • That the lockshield valve on the V5 Compact Control Pack is set correctly • Thermal resistance of floor covering is not too high, as this could reduce the floor heat output.

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Fault Finding when not using Water Temperature Control The following flow chart shows general fault finding for Uponor One Pack UFH systems. The text that follows goes into more detail on problems that may be encountered.

System should be filled with water and vented of air

Primary Side

Underfloor Heating

YES

Check demand switch to heat source

Is there heat to the flow manifold

YES

Check isolation valves are open

Open valves

YES

Are flow meters open

Fit primary pump

Is there a primary pump

YES

Open flow meters fully

Refer to the wiring flow chart

Open isolation valves

YES

Are the actuators open

YES

Zone valve not opening, check wiring, possible faulty unit

2 port zone valve operating

Isolation valves open

YES

Primary flow must be connected to flow manifold

Increase pump speed or fit a bigger pump

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Fault Finding when using Water Temperature Control System should be filled with water and vented of air

Primary Side

Underfloor Heating

YES

Check the boiler output

Is there boiler heat to the Thermostatic Control Valve

YES

Check pump isolation valve open

Unscrew pump isolation

YES

Are flow meters open

Fit primary pump

Is there a primary pump

YES

Open flow meters fully

Refer to the wiring flow chart

Set Thermostatic Control Valve to a maximum of 45oC

YES

Are the actuators open

YES

Zone valve not opening, check wiring, possible faulty unit

2 port zone valve operating

Balance lock shield closed

YES

Primary boiler flow must be to the Thermostatic Control Valve

Open lock shield, approx 3 turns

Note: Some adjustment to the lockshield valve, to less or more than 3 turns from closed, may be required due to variations in installation conditions.

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Electrical Fault Finding for Wired/Radio Controller Turn on main power

Turn room stat to max

Is there a red power light on

YES

Check live and neutral

Check fuse

YES

Possible faulty unit

UFH pump running

YES

Check relevant actuators are open

Check wiring, possible faulty pump

YES

Pump running

Check room stat is connected to relevant actuator

Actuator open

Check thermostat wiring/batteries or replace thermostat

YES

Go to the primary side flow chart

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Repairs: To make a repair to the pipe, follow the processes below: For 16mm PEX pipe Items required:

• 2 x compression adaptors, item no 1057441 • 1 x 1 x compression coupler, item no. 1006641 • Plastic pipe cutter • Denso tape Repairing the pipe:

• Isolate the damaged pipe loop at the manifold. • Cut out the damaged section of pipe. • Slide the adaptor nut and olive over each end of the pipe, prior to inserting the insert/sleeve into each end.

• Offer both ends of pipe/inserts to the compression coupler and tighten both nuts.

• Ideally, the joint will require an inspection chamber in case further maintenance is required. However, in practice this is often not practical, and the fitting is wrapped in suitable tape before burying in the screed (ensure approval with the building inspector is sought prior to doing this). • Pressure test • Location of any repair joint should be recorded for future reference.

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Frequently Asked Questions Q. Who is one-pack for? A. One-pack is for anyone who wishes to install and underfloor heating system for a floor area of up to 75m². Any competent DIY enthusiast or tradesman can install it by following the simple installation guide or watching the on-line videos. Q. Where can I get it from? A. One-pack can be ordered from any plumbing or builders merchant throughout the UK and Ireland. Simply give them the code from the on-line calculator so that they can place the order. Q. How long does the delivery take? A. Typically 3 working days. Q. What are the benefits of one pack? A. No need to wait for a quotation and a design. Simply use the on-line calculator to produce the quote there and then. When it comes to the installation just watch the videos or follow the guide to install your system. Q. What is a zone? A. It’s an area that you wish to control independently via a room thermostat. It can be one room or multiple rooms but most commonly one. Q. What is “water temperature control” WTC? A. This is used when the supply water temperature from the heat source is too high for the underfloor heating. Typically a screeded floor system requires an average water temperature of 40°c. Q. What type of room controls should I use, radio or wired? A. Each has an advantage over the other. Radio gives you the freedom to re-position your thermostats and it also cuts down on material and labour costs. Wired has a permanent power source and does not use batteries. Q. I have an existing radiator system, can I still use a one-pack? A. Yes you can, it’s very likely that you would require either a diverting valve or a two port zone valve to isolate the two different systems. It’s also likely that the underfloor heating will require water temperature control so as to reduce the higher water temperature that is typically required for a radiator system. Q. Can I expand the one-pack system in the future i.e. add another zone? A. Yes you can, all our manifolds can be coupled together so it’s easy to increase the number of ports for additional loops. Please note that it is not recommended to exceed a maximum number of twelve ports and you must always make sure that the pump size is suitable for the required out puts and pressure drops. Q. Can I use a one-pack for my conservatory? A. Yes you can although you must consider the heat losses of the room. It maybe that an additional heat source is required should you wish to use a conservatory all year round. Q. What is a manifold? A. A manifold is a central distribution point where the underfloor heating loops are connected to. It’s also used for control and isolation of the flow of water so that loops/zones can be independently controlled. Q. Where should I position my manifold? A. Ideally in the most central point that gives the most economic distribution of pipework. However if it’s just a single zone then it is best to position it within that area or as close as possible. Q. Does the one-pack contain everything that I need? A. The only thing the one-pack does not contain is either diverter valves or two-port motorised zone vales. It may not be necessary to install these depending on the heating system and the type of pack that you have chosen. If you are unsure whether your system needs them, then please consult with a professional plumber or heating engineer. Q. Can I use a one-pack for a timber suspended floor? A. One-packs are only designed for solid screed floors. Q. What type and thickness of screed should I use? A. Typicaly 65mm to 75mm thick using a ratio 4:1 sand and cement. For liquid flow screeds please consult with the manufacturer. Q. What thickness of floor insulation should I lay? A. This should be sufficient to satisfy building regulations Part L. Typically 100mm of high density floor grade PUR board is deemed sufficient. Please check with building control prior to installing. Q. What is the warranty period for a one-pack? A. Pipework is guaranteed for 25 years, electrical and mechanical items are guaranteed for 1 year. Q. What happens if I damage the pipe? A. Uponor can supply compression couplers that can be used to join the pipe together. Any joints within the floor should be suitably protected from the screed and if possible they should be made accessible. Q. What type of finished floor coverings can I use? A. It’s possible to use any type of floor covering provided the thermal resistance does not exceed the British Standard BSEN1264. For a wooden floor or similar the thermal resistance should not exceed 0.15m²k/w. For carpets and underlay the combined tog value should not exceed a value of 2. Tiled floor finishes are well suited for use with underfloor heating as they have little if any thermal resistance. Q. Can I lay underfloor heating underneath kitchen units and sanitary items? A. You can lay underfloor heating underneath kitchen units provided there are no floor fixings being used that could potentially damage the pipe. It’s recommended that you lay underfloor heating across the total floor area as the kitchen layout could change in the future. Underfloor heating is not normally placed under sanitary units as they are commonly fixed to the floor and could potential cause damage to pipes.

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Maintenance The system is virtually maintenance free with the UFH pipes having a design life expectancy in excess of 50 years. However, propriety equipment such as pumps, valves and other electrical or mechanical components are all subject to wear and failure after prolonged use. Uponor strongly recommend you take out an annual maintenance agreement with a competent Heating Engineer/Plumber to cover your entire heating system.

Installer Details Installer Name: Company (if applicable): Address:

Product Guarantee 25 years for pipe or fitting defects due to materials or manufacture when installed under normal conditions. 2 year from date of installation for electrical and mechanical products. Full copy of Product Guarantee terms is available on request. If you experience a problem with your system, you should initially make contact with the company, or person, responsible for the installation. And we suggest that you record the contact details below for future reference.

Tel Number: Installation Completion Date:

Floor Coverings Careful consideration should be given to the choice of floor finishes and coverings for floor heated rooms. It is important to choose floor coverings that are suitable for use with UFH and ideally, to maximize the system energy efficiency, select materials with relatively low thermal resistances; heat needs to pass from the water in the embedded pipes upwards to the floor surface and then emit into the room itself, however if high resistance floor coverings are used a greater amount of heat will be contained in the floor structure and lost to ground or the room below. UFH systems are designed to warm the upper surface of the floor to between 25 to 29oC when in operation. Always check suitability of floor coverings with the flooring supplier before purchasing, with particular attention given to maximum temperature limits of flooring material and adhesives, together with any special installation requirements. The floor covering thermal resistance should not exceed 1.5 m2K/W; as per harmonized British and European Standard BS EN 1264.

Vinyl & Amtico, typically have a low thermal resistance, but tend to be limited to around 27oC maximum floor surface temperature. The vinyl tiles/sheets should be glued down with a higher temperature adhesive that is suitable for use with UFH. Use manufacturers’ 2 part HT adhesive with Amtico floors. The heating should be switched off for 48 hours prior to installation and left off for another 48 hours after installation of the Vinyl floor. Carpets (> 0.5 m2K/W thermal resistance): An underlay and carpet combined value of up to 2.5 TOG is acceptable when fitted onto a heated screed floor, although the underlay used should not exceed 1.0 TOG and must be suitable for use with UFH. Most underlay is of moulded waffle sponge rubber construction and is suitable, but avoid felts, heavy rubber crumbs and polyurethane underlay. Recommended underlay includes: • Duralay Heatflow by Interfloor (Tog = 0.75) • Tredaire Technics 5 by Interfloor (Tog = 0.56) • Tredaire Technics 6 by Interfloor (Tog = 0.66)

Low resistance floor coverings (<= 0.5 m2K/W thermal resistance): Ceramic tiles, marble, slate, limestone, flagstones are all excellent materials for covering heated screed floors, especially in areas where heat losses may be excessive. Use a quality two part flexible adhesive, rated to at least 50oC, to continuously bond tiles/slabs to the floor substructure and flexible edge joints to avoid cracking. Polished Screed, which is highly conductive and well suited for use with UFH.

• Roma by Ball & Young (Tog = 0.8) For timber suspended floors the additional resistance imposed by the floor boards need to be taken into account, therefore low TOG value carpets should be used. Solid wood boards up to 25mm thick, engineered hardwood flooring up to 20mm thick and laminate boards are all compatible with UFH. For Solid wood it’s important to maintain moisture content of about 10% when laying. When installing floating floors onto screed a thin low thermal resistance underlay is required, such as: 2.75mm thick Duralay Heatflow for laminate & solid wood floors (Tog = 0.35).

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Uponor Limited (â&#x20AC;&#x153;Uponorâ&#x20AC;?) guarantees [to the original purchaser/ customer] that pipes and fittings sold by it are free of defects in materials or manufacture under normal conditions of use for a period of 25 years and in case of electrical and mechanical products for 2 years from the date of installation. This guarantee only applies to the products stored, installed, tested and operated in accordance with the fitting instructions issued by Uponor and valid at the time the products were installed. Where a claim is made during the guarantee period and products are proven to be defective in materials and/or manufacture at the time of delivery, Uponor will supply replacement products free of charge. This is the exclusive remedy under this guarantee. Uponor disclaims any warranty or guarantee not expressly provided for herein, including any implied warranties of merchantability or fitness for a particular purpose. Uponor further disclaims any and all responsibility or liability for losses, damages and expenses, including special, direct, indirect, incidental and consequential damages, whether foreseeable or not, including without limitation any loss of time or use or any inconvenience arising from the ownership, installation or use of the products sold hereunder. This guarantee does not affect the statutory rights of the consumer.

Copyright ÂŠ Uponor (Uponor Limited.) Reproduction of any part of this publication for any purpose is not permitted without the prior written permission of Uponor Limited. The contents of this brochure are provided for guideline only, please consult our technical manuals for full up-to-date information. Uponor reserves the right to alter specifications and operating parameters for all their Underfloor Heating and Plumbing & Heating Systems at any time as part of its policy of continuous product development. Care has been taken to ensure that the information in this price guide is correct at the time of going to press. Uponor Limited reserve the right to alter prices and the details of designs and performance of products without notice. E&OE.

UIG-OP-UFH-April 2012

Uponor Limited Head Office Gilmorton Road Lutterworth Leicestershire LE17 4DU

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T 01455 550355 F 01455 550366 E enquiries.uk@uponor.com W www.uponor.co.uk

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