Low-Build 15 Underfloor Heating Product and Installation Guide Surface heating and cooling

Uniclass
JT20 L75624
EPIC
L634 L511
CI/SfB
March 2012
(56.3)
UF434
Surface heating and cooling
solutions by Wavin
Low-Build 15 Underfloor Heating
Product and Installation Guide
Solutions for Essentials
About Thermoboard
Underfloor Heating
from Thermoboard
Advanced UFH technology
Specialist expertise
Thermoboard is the name for underfloor heating & cooling
As UFH specialists, Thermoboard provides more than the
solutions from Wavin. Our comprehensive range covers all
systems and components alone. We ensure that specifiers,
building construction types typically used in the UK and all
planners and installers are able to receive the full benefit of our
types of floor constructions.
extensive experience.
Thermoboard advanced UFH technology has been developed
System selection tools, information and guidance are all available
for both concrete-based floors and timber floors in new build
online and in print for even the smallest job. Our QuickCalc facility,
and refurbishment projects. They provide cost-efficient
accessed via www.thermoboard.co.uk, gives instant online
installations for all types of environment, including residential
project quotations and bill of materials.
and light commercial buildings.
For larger and more complex projects, our FullSpec service
What’s different about Thermoboard UFH
Thermoboard UFH systems have been designed to combine
includes complete warrantied system design, with CAD drawings
and installation instructions, a dedicated project manager and
direct-to-site delivery of all materials.
easy installation with consistent heating performance in service.
No specialist tools are needed for fitting.
The Low-Build 15 UFH system is an example of our long tradition of
innovation. At Thermoboard, our constant aim is to help the installer
work more efficiently and with more certainty of a successful
outcome. The Low-Build 15 system can be supplied under either of
our service facilities: QuickCalc and FullSpec.
A Low-Build 25 System is also available.
UFH
it’s what
we do
2
Telephone: 01392 444122
Fax: 01392 444135
Low-Build System Introduction
UFH for existing floors
Key benefits
Thermoboard’s Low-Build systems are designed to be installed
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directly onto existing floors, with minimum build-up and no major
disruption. They make retrofitting of plumbed UFH a more practical
Low build up height: 15mm (excluding optional
load-bearing ply layer)
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and cost-efficient option for private home refurbishment.
Practical universal panel design: incorporating
end-return, flow and through-connect channels
Previously, this would have involved digging up solid floors or
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Lightweight panel: easy to handle
lifting floorboards – or a significant rise in floor level.
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Easy to cut and install: only one person required**
More practical and cost-efficient
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Robust: able to withstand point loading
The Low-Build 15 system’s ultra-slim polystyrene panels are
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Instant online project quotations are available for
pre-routed to create a channel for 10mm polybutylene pipe.
this system using Thermoboard QuickCalc at
When laid, these panels cause minimal rise in floor level and
www.thermoboard.co.uk
less disruption to doors and skirting during installation.
Electric mat systems have often been used for similar
* based on using a SEDBUK A Rated boiler, and wet UFH vs
electric UFH systems at typical 2010 domestic energy prices.
** qualified electrician required if mains-connected controls fitted.
applications because of their shallow profile. However, by
comparison, plumbed UFH can save as much as two-thirds
of the energy costs* of electric systems in operational service.
Practical design for simpler installation
This system does not require the purchase and placing of
separate end-return panels. One end of each Universal Panel
incorporates all the necessary channel options to help the
installer quickly achieve the specific pipe layout that the
job requires.
Email: [email protected]
www.thermoboard.co.uk
3
Applications and Specifications
Where can Low-Build UFH be installed ?
Thermoboard Low-Build 15 UFH system can be installed directly
Any type of floor covering can be used with this system, including:
onto any existing solid or timber floor provided that it is flat and level.
carpets, hardwood, vinyl or tiles. In some cases, it may be
This system is primarily designed to enable the easy addition of
advisable to add a load-bearing ply layer on top of the system
UFH to individual rooms undergoing refurbishment.
panels (see table below).
Typical examples include:
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Kitchens
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Conservatories
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Bathrooms
Floor Covering
Suggested Supporting Layer
Vinyl
6mm Plywood *
Tiles
12mm T&G Plywood **
Laminate
None
6mm Plywood *
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Newly-separated en-suites for bedrooms
Carpet
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Garage conversions
Engineered Wood
None
Solid/Natural Wood
None (but, will require
15mm battens between
panels to secure flooring)
Low-Build 15 UFH has been designed for simple installation covering
up to 26m2 (3 circuits). For areas greater than 26m2, please contact
Wavin to speak to a project consultant regarding design and layout.
* The 6mm Plywood supporting layer consists of two 3mm Plywood layers
glued together. The top layer should be laid so that the edges of the sheets
on the bottom layer align with the centre of those on top.
** 6mm Plywood may be suitable for certain tile types. Consult with tile
manufacturer.
Typical pipe installation layouts
4
as referred to in Step 4 of the Installation Instructions shown on p.9
Typical Kitchen
installation layout
Typical Conservatory
installation layout
Typical L-shaped room
installation layout
Typical square room
installation layout
Telephone: 01392 444122
Fax: 01392 444135
Product Specification and Component List
Connection and control options
Product specification
A Low-Build 15 UFH circuit may be connected to an existing heating
Polystyrene panel, incorporating thin aluminium heat diffuser layer,
source, whether that is serving other UFH circuits or radiators.
with pre-routed channels for placement of 10mm polybutylene pipe.
Temperature control may be linked to the main heating programme,
Universal design to eliminate requirement for separate end-return
or operated as a separately controlled heating zone with its own
panels.
thermostat. Separate control gives the homeowner the option of
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Panel size: 1200x 600x 15mm
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Channels at 150mm centres
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Maximum circuit length: 60m, covering 9m2
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Maximum floor area: 26m2, up to 3 circuits
selected underfloor heating outside the normal heating season –
at cool times of day during Summer months, for example.
For areas greater than 26m2, please contact Wavin to speak to
a project consultant.
Low-Build 15 system components
Room /Heating Zone Size (m2)
6
8 12 16 20 24 26
Component/Pack
Pack Code
Universal Panel
(10-pack)
92UH310
1
-
2
1
-
2
1
Universal Panel
(15-pack)
92UH315
-
1
-
1
2
1
2
Pipe Coil
10mm x 60m
10UH060
1
1
2
2
3
3
3
Mixing Unit
88UH211
-
1
1
1
1
1
1
Isolation Valves
(pair)
88UH311
-
1
1
1
1
1
1
1-Port Manifold
Pack
92UH101
-
1
1
1
1
1
1
Additional Port
Pack (for manifold)
92UH103
-
-
1
1
2
2
2
Small Room
Connection Pack
92UH006
1
-
-
-
-
-
-
Universal 1200x600mm
laminate panel.
We’ve designed a system
incorporating end-return and
flow channels, as well as
through-connect channels for
placing 10mm polybutylene
heating pipe.
EXTRA OPTION for heating zone control
independent of existing main heating
system: Thermostat 52UH278
Pre-routed polystyrene
panel. Light but robust and
able to withstand point
loading. With pipe channels
at 150mm centres to
ensure consistent output.
Aluminium diffuser layer.
Built-in reflector to direct
heat up through chosen
floor covering.
Email: [email protected]
www.thermoboard.co.uk
5
Installation Instructions Overview
Tools required for cutting
Panels and Pipe
Hints and tips
PIPE
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Utility Knife
When cutting or trimming Thermoboard 10mm UFH pipe
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Pipe Cutter
for connection to the manifold
Tools required for mounting and
connecting the manifold
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Ensure pipe is cut square with appropriate cutter
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Do NOT use a hacksaw, wheeled tube cutter or utility knife
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Remove any burrs or roughness – as per normal plumbing
Areas greater than 6m2 (Mixing Unit)
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Spirit Level & Pencil
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Drill & Drill Bits for mounting (fixings supplied)
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Wrenches for making connections
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Screwdrivers suitable for making electrical connections
Good Practice
When placing the pipe
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Do NOT bend Thermoboard 10mm pipe more tightly than
a radius of 60mm
Areas less than 6m2 (Small Room Connection Pack)
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If pipe is kinked or damaged, it MUST be replaced
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Use the pipe packaging to control the pipe whilst uncoiling
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Spirit Level & Pencil
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Uncoil pipe from the inside of the coil
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Drill & Drill Bits for mounting
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Use pipe supports and clamps to secure the pipe work
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150mm Core Drill required for flush installation
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Wrenches for making connections
GENERAL
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Screwdrivers
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where it converges below the manifold
Do not install UFH in floor areas that will be covered by
major fixtures
EXAMPLES
Preparation
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– in Kitchens: under cupboards, work surfaces, oven, fridge freezer
Make sure the existing floor (onto which Low Build UFH is to
be laid) is flat, level, clean and dry
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– in Bathrooms: under sanitaryware, bath, shower
NOTE: It is possible to install low build panels with no pipework
If extending an existing heating system ensure the boiler has
to maintain level floor height for kitchen appliances
sufficient capacity to power the additional circuit(s). If replacing
existing heating circuits the heat demand will not change and
TESTING
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the existing boiler will be sufficient
Use a Hydraulic Pressure Tester (available from most hire shops)
STEP-BY-STEP GUIDE
Low-Build
UFH
in 8 easy
steps
Step 1 Select suitable location for
the Control System
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Control system (either the Small Room Connection Pack or the
Single Zone Control System) must be installed within the room
area to be heated
NOTE: Mixing Unit can be located outside of area to be heated
if required (max length 15m from manifold connection)
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Ideal height is 200mm from floor
NOTE: For installations requiring 3 circuits (greater than 20m2) the
Single Zone Control System MUST be located centrally in the room.
For installations requiring up to 2 circuits it can be located in the
corner or centrally
For areas greater than 6m2
or
for areas less than 6m2 see
page 8
6
Telephone: 01392 444122
Fax: 01392 444135
Installation Instructions for Areas Greater than 6m2
Step 2 Assemble the
Single Zone Control System
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The Single Zone Control System consists
15mm Adaptor
of 1 Port Manifold Pack (92UH101),
15 x 10 x 15mm
Branched
Reduced Tee
15mm
Blanking
Peg
Isolation Valves (88UH311) and the Mixing
Unit (88UH211)
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The Single Zone Control System can
accommodate between 1 and 4 heating
Additional Port Pack
92UH103
circuits, which will work together as a
single heating zone
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Connect the Isolation Valves (88UH311) to
15mm Adaptor
the Mixing Unit (88UH211)
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15 x 10 x 15mm
Branched
Reduced Tee
15mm
Blanking
Peg
Connect the 1” to 15mm Adaptors to the
Mixing Unit
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Insert a 15x10x15mm Branched Reduced
Tee into each 1” to 15mm Adaptor
If more than one circuit is required, attach a
Manifold Additional Port Pack 92UH103.
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Insert an additional 15x10x15mm
Branched Reduced Tee in to the existing
88UH311
If locating Mixing Unit outside area to be heated
Isolation
Valves x2
and Fibre
Washers
Connect to
22mm heating
supply.
15mm Hep2O Pipe
and Pipe Inserts
15mm Straight
Connector
Branched Reduced Tee (see opposite)
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Insert 15mm Blanking Pegs into the end
of the last 15x10x15mm Branched
With Pipe Inserts in place fit the pipe (max length 15m)
into the 15mm Adaptors. Fit a 15mm Straight Connector
to the pipe end where it leaves the area to be heated.
Reduced Tee
This completes the Control System assembly.
If the Mixing Unit is to be located outside
of the area to be heated:
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With pipe inserts in place insert standard
15mm Hep2O pipe (max length 15m) into
the 15mm Adaptors
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Connect a 15mm Straight Connector on
to the end of the 15mm pipe where it
leaves the area to be heated
Step 3 Mount the Control
System
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Mount the Control System on a suitable
wall using the screws provided
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Ensure bracket is vertical and the pump
shaft is horizontal
NOTE: If it is intended to mount the Mixing
Unit within a floor space:
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Loosen the pump and rotate so the
printed black face of the pump is vertical
before re-tightening
Move on to Step 4, page 9
Email: [email protected]
www.thermoboard.co.uk
7
Installation Instructions for Areas Less than 6m2
Step 2 Mount the
Connection Pack Casing
Connection Pack should be located close to
Ø 150mm
the pipe circuit to be installed.
Wall recessed
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Use 150mm core drill to drill recess hole
in wall
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Chase wall for flow and return pipework
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Mount casing using screws provided
Wall mounted
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Wall Recessed and
chased for pipework
Wall Mounted
Use casing to mark screw positions
on wall
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Mount casing using screws provided
Step 3 Assemble the Small
Room Connection Pack
(92UH006)
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Connect the 15mm straight tap
connectors to the Small Room Connection
Pack Mixing Unit
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Insert one of the 15x10mm Socket
Reducers into the return tap connector (left)
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Insert the second 15x10mm Socket Reducers
into another 15mm Straight Connector
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This completes assembly ready for pipe
connection
Mixing Unit
Casing
15 mm
Straight Tap
Connector
15 x 10mm
Socket
Reducer
Pipe Insert
15 mm
Straight Tap
Connector
Connect to
15mm heating
supply
15 mm
Straight
Connector
15 x 10mm
Socket
Reducer
10mm Pipe
Pipe Insert
10mm Pipe
8
Telephone: 01392 444122
Fax: 01392 444135
Laying Panels and Inserting the Pipe
Step 4 Lay Universal
Panels
Refer to typical pipe layouts on page 4 for
guidance according to room shape/type.
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Lay the Universal Panels with flow and
returns against the walls at opposing ends
of the room
NOTE: Position the flow/returns along the
wall on which the Control System is mounted
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If any panel requires trimming to size
– Place 2 panels in position with one
overlapping the other
– Mark edge of overlap of upper panel
on lower panel using a marker pen
– Using a utility knife cut the panel along
the marked line using a straight edge
such as a spirit level
– Ensure cut edge is clean
Step 5 Insert the Pipe
When installing more than a single circuit
(greater than 8m2)
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Divide the heating zone into equally sized
Fig. B
areas to be heated by each pipe circuit
For each circuit
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Cover and Control
Knob
Starting from the Control System, feed the
pipe into the channels, finishing back
at the Control System
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Use the 10mm curved bend supports at
the base of the wall below the Control
System to create a tidy installation
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Fig. A
RE
TU
RN
Cut the heating pipe to length and insert
the support sleeves
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Push
inserts
into
10mm
pipe
Insert the pipe into the flow and return
ports on the Control System. (see Fig A
FL
OW
for areas greater than 6m2 and Fig B for
areas less than 6m2)
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Pipe
Clamps
Secure the pipe to the wall with the Pipe
Clamps
Pipe
Clamps
For areas less than 6m2 (using Small Room
Connection Pack Fig. B)
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Attach the Control Knob and Cover over
the Connection Pack Unit
Email: [email protected]
Curved
Pipe
Supports
FLOW
RETURN
Curved
Pipe
Supports
www.thermoboard.co.uk
9
Connecting the System
Step 6 Connect to the heating system
Whether installing the Low-Build 15 System into an area less than
Please follow the relevant set of Connection Diagrams
6m2 or greater than 6m2, the system can be installed with or without
for your system configuration, paying close attention to the
boiler interlock (Option A or B below).
diagram notes.
A
With Boiler Interlock
Fri
°C
H
All components must be installed
Fri
Radiator Thermostat
as existing
10:08h
ROOM TEMP
Plumbing Connections
52UH278
10:08h
ROOM TEMP
°C
A
H
UFH Thermostat
A
Flow Watch
Thermostat
set to 75ºC
Radiators as existing
and earthed in accordance with
88UH211
local regulations.
92UH006
or
UFH
Control
Pack
OFF
UFH
Zone Valve
required
ON
Radiator
Zone Valve
as existing
Room Connection Pack (92UH006) in
place of the Single Zone Control
OFF
For installations using the Small
ON
Electrical Connections
Flow Pipe
System the Flow watch thermostat
and UFH Pump are not installed and
terminals 6 and 7 should be linked
Return Pipe
To Boiler
together with a short length of wire.
should not be installed in Wet
Rooms, e.g. Bathrooms. When
controlling Wet Rooms, the UFH
230V AC - 50Hz Supply
Taken from the Heating
System Fused Spur
Room, with the Remote Sensor
Junction Box
(Not Supplied)
UFH
Zone Valve
(Not Supplied)
1
2
3
4
5
6
52UH278
Fri
10:08h
UFH
Thermostat
ROOM TEMP
°C
H
A
E
C
1
Flow Watch
Thermostat
(Part of
88UH211
Assembly)
L
E
N
UFH
Pump
(Part of
88UH211
Assembly)
7
Orange
Grey
Blue
Grn/Yell
Brown
Probe installed inside the Wet Room.
B
E
N
L
LS
To Boiler Interlock Terminals LR
Thermostat should be located in a
suitable location outside of the Wet
RT1
RT2
L
N
E
Load
Terminals for remote temperature sensor
(See thermostat instructions for details)
The UFH Thermostat (52UH278)
Without Boiler Interlock
Fri
Plumbing Connections
Radiator Thermostat
as existing
10:08h
ROOM TEMP
°C
H
A
For installation using the Small
Room Connection Pack (92UH006),
Radiators as existing
88UH211
no power supply or any other
or
92UH006
electrical connections are required.
UFH
Control
Pack
All components must be installed
and earthed in accordance with
ON
ON
OFF
local regulations.
Radiator
Zone Valve
as existing
OFF
Flow Watch
Thermostat*
set to 35ºC
Flow Pipe
*Flow Watch Thermostat removed from 88UH211 and
mounted on heating supply (Does not apply to 92UH006)
Return Pipe
Electrical Connections
As the Small Room Connection
Pack (92UH006) does not require a
power supply, the following
diagram only relates to installations
230V AC - 50Hz Supply
Via 3A Fused Spur
Junction Box
(Not Supplied)
E
N
L
E
N
L
1
2
3
UFH
Pump
(Part of
88UH211
Assembly)
4
2
E
C
using the Single Zone Control
To Boiler
Flow Watch
Thermostat
(Part of
88UH211
Assembly)
System.
10
Telephone: 01392 444122
Fax: 01392 444135
Testing and Commissioning
Step 7 Pressure Testing
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Before connecting to the existing heating system
– Fill the Low-Build 15 system with water.
– Using a Hydraulic Pressure Tester pressurise to minimum of
1.5 x operating pressure of the boiler for 2 hours (typically
mains water pressure will suffice).
– If any joints are leaking, remake the joint.
– If any pipework is damaged and leaking the pipe circuit
must be replaced.
Step 8 System Commissioning
(for areas greater than 6m2)
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Set the pump and temperature:
– Commission the Grundfos circulator in accordance with
the manufacturer’s instructions and set it to speed III.
– Adjust the flow water temperature by turning the
thermostatic actuator. Refer to the table in the Quick
Install Guide supplied with the Mixing Unit.
– Pull out the discrete white lock ring around the base
of the blue thermostatic actuator, rotate until the
2 notches line up either side of the white arrow
and push back into position.
– Set the Flow Watch thermostat to 75ºC if
installed with boiler interlock, 35ºC if installed
without boiler interlock.
everything
you need
for UFH
success
Email: [email protected]
www.thermoboard.co.uk
11
Surface heating and cooling
solutions by Wavin
Thermoboard –
ensuring the right solution
Under the Thermoboard brand Wavin offers solutions for
surface heating and cooling for domestic and light commercial
environments. Thermoboard systems and services are
designed to enable speedy selection and correct installation
of the right solution for each situation – ensuring project
success, with complete peace of mind.
UFH, it’s what we do.
UFH
it’s what
we do
Wavin
Underfloor Heating Division
The Dart Building
Grenadier Road
Exeter Business Park
Exeter, Devon EX1 3QF
Tel: 01392 444 122
[email protected]
www.thermoboard.co.uk
Wavin operates a programme of continuous product development, and therefore reserves the right to modify or
amend the specification of their products without notice. All information in this publication is given in good faith, and
believed to be correct at the time of going to press. However, no responsibility can be accepted for any errors,
omissions or incorrect assumptions. Users should satisfy themselves that products are suitable for the purpose and
application intended.
UF434
Solutions for Essentials