Uniclass JT20 JV50 L75624 EPIC L634 L2242 L511 CI/SfB (56.3) April 2006 Underfloor Heating Available Through Merchants UF417 Design and Installation Guide STANDARD UNDERFLOOR HEATING COMPONENTS FOR SMALL NEW-BUILD RESIDENTIAL PROJECTS Intelligent Solutions for Heating Projects UNDERFLOOR HEATING Standard Product Range: Design and Installation Guide About OSMA UFH A partnership of experience OSMA Underfloor Heating combines the specialist skills and experience of two companies: Wavin is Europe’s largest supplier of Versatility, Consistency and Reliability What’s different about OSMA Underfloor Heating Giving you a choice OSMA UFH products have been designed product choice including floor panels with to provide the highest possible heating pre-cut channels in the insulation to performance while using materials that will indicate the positioning and spacing for last throughout the life of the building. installation of the pipe on site The products combine easy installation Alternatively, you can opt for a basic system with consistent performance. They ensure which allows the installer to set the pipe that the power output from the floor is centres and layout during installation. plastic pipe systems in terms of product range, innovation, logistical services and geographical presence ThermoBoard is one of the UK’s major suppliers of underfloor heating systems. OSMA plumbed systems offer you a determined by the product rather than by the skills or experience of the installer. The company has pioneered the development of product-based solutions OSMA innovation to underfloor heating for more than a OSMA UFH products are as easy to use decade as conventional radiators. They require little or no previous underfloor heating The UK’s most advanced UFH technology experience. No specialist tools are OSMA UFH technology has been They enable any installer to work more developed to suit all building construction quickly to achieve a high quality result. types typically used in the UK – both OSMA UFH systems for domestic concrete-based floors and timber floors. applications include plumbed systems for It provides innovative, cost-efficient all types of floor construction, including: solutions for all types of environment, including residential, commercial and public buildings. For residential projects This publication provides guidance on the design and installation of underfloor heating using OSMA UFH components available through Merchant Stockists. These products are primarily designed for use in new-build residential applications up to four circuits. 2 needed for successful installation. SALES AND TECHNICAL ENQUIRIES 01392 444122 Sand/cement and liquid screeds Timber battens and timber joists Fully floating timber floors The range available through Merchants is specifically designed to offer efficient and effective solutions for small and medium sized heating projects. These may include: extensions, refurbishment of individual rooms, conservatories or single dwelling installations. FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Standard Product Range: Design and Installation Guide Contents Further Information Timber Floors INTRODUCING UFH OSMA Underfloor Heating products 2-4 Timber Joist Products 17 Fully Floating Floor Products 18 Battened Floor Products 19 are available for OSMA Underfloor DESIGN Design Principles 5-6 Design Procedures 7-10 System Controls General Considerations Mixing Control Units Pressure Testing 23-24 Sales and Technical Enquiries Tel: 01392 444122 Fax: 01392 444135 Design Planner Screeded Floors Basic Products for Screeded Floors System Plates To obtain copies, please contact: REFERENCE SITEWORK 14 15-16 Product Guide 20-22 System Verification 12-13 Heating Standard Products Range: Trade Price List 10-11 OSMA UFH SYSTEMS/ PRODUCTS Product Range The following related publications 25 General Information / Technical Assistance 27 The OSMA UFH Guarantee OSMA Underfloor Heating is the only UFH supplier in the UK which engineers and manufactures its products. Each system uses the highest specification components. All systems described in this Design and Installation Guide are directly backed by a full product guarantee provided that installation has been in accordance with the instructions provided. Unlike some other UFH suppliers, this guarantee is independently underwritten by insurance. For full details/terms, contact OSMA Underfloor Heating. NOTE: For plumbed systems, this Guarantee presumes the use of OSMA Flexible Plumbing Pipe (OsmaGold). The Guarantee may NOT apply if pipe from another manufacturer is used. OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Introduction . Contents 3 UNDERFLOOR HEATING Introduction / Standard Product Range Introduction UNDERFLOOR HEATING RADIANT HEAT The maximum floor temperature should Underfloor heating is the most comfortable As soon as the floor surface becomes not normally exceed 29°C (although form of heating. It is unobtrusive, warmer than the air in the room, it begins 34°C is acceptable in bathrooms). economical, safe, hygienic and virtually to radiate. Radiant energy emitted from maintenance-free. It offers the best the floor is absorbed by all the other long-term method of heating a building surfaces in the room. These surfaces because it uses low-temperature water, warm up and begin to radiate, thereby which in future can be provided without providing an all-round comfortable having to burn fossil fuels. warmth in the room. The air in the A UFH system is easily formed. Instead of hanging conventional radiators on room only becomes warm because it is in contact with these warm surfaces. THE OSMA STANDARD PRODUCT RANGE The OSMA Standard Product Range has been designed to enable anyone who is familiar with radiator heating to confidently design and install underfloor heating within standard concrete and screed or timber floor types. the wall, you simply make the floor itself ENERGY EFFICIENT a large-surface heat emitter by For product range and selection, Most new-build constructions can be incorporating warm water pipe within see pages 12-19. kept warm with heating power in the the floor construction. range 35-75W/m2. This power output can be achieved with floor surface temperatures of just 24-27°C. Larger projects For larger and more complex underfloor heating (and cooling) projects, OSMA UFH has a range of alternative products available. OSMA UFH has extensive experience of partnering with the largest contractors on the most technically demanding projects and can provide a bespoke design service, with direct-to-site delivery. 4 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Design Principles Design Principles An underfloor heating system consists of: In-floor components and heating pipe Flow controls of the water into the floor Room temperature control MINIMISING HEAT LOSS If you use a boiler designed to heat the With any form of underfloor heating it is water to a higher temperature, it is important to minimise the amount of heat necessary to add a water mixing control that is lost to the underside of the floor. unit to reduce the temperature of the Insulating ground floors to Building These are very similar to the elements Regulation standards is generally sufficient of any radiator system. The principle to restrict the heat transfer downwards. difference is that the heat emitter is built However, consideration should be given into the floor rather than hung on the to installing higher levels of insulation, wall. in line with the trend for increases in The same form of Heating Primary is regulatory requirements. used to distribute warm water around On upper floors, Building Regulations the building. Where a spur would be Part E now require that acoustic taken off the Primary to a radiator, the insulation must be incorporated between same kind of spur is taken instead to a joists or within the make up of a solid water flow controller, and through this floor. This also provides effective thermal to the pipe circuits in the floor. insulation. The temperature of each room is WATER TEMPERATURE controlled using a room thermostat and If you are designing an underfloor heating a valve to turn ON/OFF the flow of water system to heat an entire building, some into the floor. modern combi and condensing boilers LOWER WATER TEMPERATURE are able to supply water, at the required An underfloor heating system uses water underfloor heating system. Such a at a much lower temperature than is boiler’s internal pump can be used to required by radiators. circulate the water around the pipe To achieve the necessary heat output, a water entering the underfloor heating system (see pages 20-22). lower temperature, directly to an circuits. floor surface temperature of maximum 29°C is generally required. Depending on the conductivity of the floor and the floor finish, this may be achieved with a water temperature in the underfloor pipes of between 40°C and 60°C. Such temperatures can be easily produced from a heat pump or from solar heating. By contrast, to generate sufficient air convection, radiators generally require water at 70-80°C, and this can only be produced easily by burning fossil fuels. OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Introduction . Design Principles 5 UNDERFLOOR HEATING Design Principles Design Principles continued Control Pack with Manifold WATER FLOW CONTROL Whichever type of boiler is used, for projects larger than 20m2 the heated water is generally distributed to separate pipe circuits via a manifold. Electrically operated actuators on each branch of the manifold, linked to a room thermostat, can be used to control the flow of water into the separate circuits/zones. Where necessary, a Water Mixing Control Unit can be added to the front of the manifold (see pages 20-22). COMBINED SYSTEMS It is possible to add a section of underfloor heating to a radiator system, provided: the boiler has sufficient spare capacity the diameter of the spur from the Primary to the water mixing controller is large enough to deliver the quantity Single Port Manifold of heat required by the underfloor heating There are two ways to ensure that the high temperature water from a radiator system does not cause the floor to become too hot: In small projects that involve just one zone and a maximum area of about 20m2, it is possible to use Single port manifold and control pack: If individual room control is required Water Mixing Control Unit for One or Two Circuits and water is to be taken from the boiler primary pipework, this unit allows a small area to be run independently of an existing central heating system. It wil require a simple by-pass and a thermostat which must be purchased separately. Mixing Control is used: High temperature water from the radiator Primary is mixed with water returning from the floor to produce a stream of water into the floor at a temperature that can be adjusted to a level which will not result in the floor overheating. 6 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Design Procedures 1 How Much Heating Power Do I Need ? Experience shows that in most new or refurbished buildings complying to April 2002 Part L Building Regulations, heating power of 35-75W/m2 is sufficient to maintain internal temperature of 20ºC. Provided the floor finish thermal resistance is not greater than 0.150 m2 K/W (1.5 Tog), this amount of power output can be generated by any of the forms of UFH described in this Guide, using pipe at 200mm centres. Consequently, it may not be necessary to make detailed heat loss calculations. Where a space is to be heated that may have higher heat losses, the power requirement should be calculated, using the calculation method outlined on page 11. Use this calculation method for: rooms with large areas of glazing Underfloor heating is an effective way of form of heating may be required to heating a conservatory. However, the high maintain an internal temperature of 20°C buildings constructed to pre-April rate of heat loss through the extensive on occasions when the external 2002 Part L Building Regulations areas of glazing means a supplementary temperature falls below 7-8°C. rooms with more than 2 external walls 2 CONSERVATORIES What Heating Power Will UFH Provide ? The power output equation for UFH is: Occasionally, detailed heat loss The type of floor finish – for example, ( calculations – as prepared in accordance tiles, timber or carpet – or the spacing with the calculation method outlined on of the heating pipe can affect the transfer page 11 – show that 95W/m2 power of heat from the floor through to the output is insufficient. This can sometimes floor surface. ) floor surface room air x 10.6 W/m2 – temperature temperature As a consequence, it can be seen that with a floor surface of 29°C and air temperature of 20°C, power output will 2 be 95W/m . In most projects, this will be sufficient. happen in bathrooms, for example, where the available floor area is small by comparison with the heat loss. In such cases, the underfloor heating can be 29ºC is the maximum design surface supplemented by installing a towel temperature (above that the floor may radiator perhaps plumbed in as part of become uncomfortable, although in the UFH circuit. Use these Tables not only to confirm that the power output will be sufficient but also to determine the Flow/Return temperatures that will be required. Bathrooms the design temperature may be increased to 34°C). OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Design Principles . Design Procedures 7 UNDERFLOOR HEATING Design Procedures UFH System Output (W/m2) Screeded Floors Resistance of Floor Finish m2 K/W 200 mm 300 mm 200 mm 300 mm 200 mm 300 mm 10mm Timber 0.070 123 101 107 88 91 75 20mm Timber 0.140 90 79 78 69 66 58 10mm Carpet/Hard Tile 0.100 113 94 98 82 83 70 10mm Carpet & Underlay 0.150 91 80 79 70 67 60 4mm Vinyl – Linoleum 0.018 150 114 131 99 112 85 10mm Ceramic Tiles 0.012 151 118 132 103 112 87 25mm Marble 0.011 140 111 122 97 103 82 Floor Finish Flow/Return Temperatures & UFH Pipe Centres (mm) 65-55°C Floor Finish 55-45°C UFH System Output (W/m2) Floating & Battened/Joisted Floor Resistance of Floor Finish m2 K/W 60-50°C Flow/Return Temperatures & UFH Pipe Centres (mm) 65-55°C 60-50°C 55-45°C 200 mm 200 mm 200 mm 10mm Timber 0.070 79 75 56 20mm Timber 0.140 86 65 64 10mm Carpet/Hard Tile 0.100 75 70 52 10mm Carpet & Underlay 0.150 63 61 47 4mm Vinyl – Linoleum 0.018 86 55 64 10mm Ceramic Tiles 0.012 87 75 65 25mm Marble 0.011 79 76 59 EN1264 Theoretical Heat Output for Screed, Floating & Batten/Joisted OSMA UFH systems 8 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Design Procedures 3 What Type Of Floor Do I Have? Generally, the options include – 2. Screw Clips grooved panels of chipboard or plywood. If the insulation is soft – for example, The floor deck is held in place purely by its standard density or high density expanded own weight. polystyrene such as Jablite or mineral The Standard Product Range includes Timber battens wool such as Rockwool – staples will 50mm thick Floating Floor Panels that Softwood joist not grip the pipe sufficiently tightly. incorporate pre-cut pipe channels with Screw Clips should be used. factory-fitted aluminium heat diffusers, and 3. System Plates a polythene film fixed over the top of these. These are vacuum-formed plastic panels They are used in place of plain insulation with moulded pipe grippers that are laid panels to support a fully-floating deck. over the top of whatever insulation you The conductivity of OSMA Floating Floor purchase. System Plates hold the pipe Panels is much lower than expanded SCREED securely, and at regular spacings. polystyrene, and this helps minimise Most screeded floors are formed by laying OSMA System Plates allow the pipe to downward heat loss. sand/cement mix 65-75mm thick over be set as close as 50mm centres, which insulation. Before the screed is laid, edge is very useful when taking pipe through insulation should be set all round the Timber Battens, Joists and I-Beams corridors to several separate rooms. periphery of the room to allow for thermal Battens are used either where the floor The pipe can also be held diagonally. loadings are to be higher than can be Whatever the method chosen, attention supported by a fully-floating floor or where should be paid – the floor deck is to be formed from planks Screed Fully-floating timber Manufactured timber I-beams Once the type of floor construction has been determined, the appropriate products may be selected from the Standard Product Range (see pages 12-13). movement in the screed during the year. When creating an underfloor heating system, heating pipe is fixed to the top of the insulation, just before the screed is laid, so that the heating pipe ends up within the thickness of the screed. where the ends of the pipe circuit(s) come together below the site of the Water Flow Controller/Manifold We recommend that the heating pipe at the junction between floor and wall, is set at 200mm spacing, which is where the pipe changes from running sufficiently close to enable the full heating horizontally to vertically rather than be allowed to fully float. Softwood joists are commonly used in Intermediate Floors although manufactured I-Beams are often used instead because they can be stronger and are more stable dimensionally. performance to be achieved, whilst In most underfloor heating systems, these minimising the amount of pipe used. details are the only parts that are visible. The Standard Product Range provides 3 The OSMA Standard Product Range different ways of securing the pipe to the includes accessories such as Sweep top of the insulation: Bends and Clamps to ensure that these 1. Staples that must be nailed down to a support, details can be achieved neatly. The Standard Product Range includes 50mm thick Batten/Joist panels, similar to Floating Floor Panels but 340mm wide, which are intended to fit between 50mm thick battens and automatically space these at nominal 400mm centres, or to be fitted between softwood joists at similar for example, extruded polystyrene such FULLY-FLOATING TIMBER FLOORS as Polyfoam or Styrofoam, or polyurethane These are floors where panels of insulation be fitted up from below between I-Beams. such as Celotex – staples will provide a are used to support a timber floor deck secure fix for the pipe. that is normally formed from tongued and If the insulation you purchase is firm – 4 centres, either from above or below, or to For Product Range, see pages 12–13 Pressure Testing Underfloor heating pipe is arranged in CONTINUOUS PIPE LENGTHS or Heating Panels have been installed in an separate pipe circuits within the floor If the pipe circuit is a continuous pipe I-Beam joisted floor, each circuit should construction and terminated at the water length, the test pressure should be 3 bar. be tested to at least 18 bar. flow controller. Prior to connection to the This will be sufficient to determine whether After each pipe circuit has been pressure- water flow controller, each pipe circuit the pipe has been punctured during tested, connect the pipe ends to the Water should be pressure-tested, using an installation, by a nail for example. Flow Controller. Do not pressure test pipe PIPE LENGTHS WITH FITTINGS circuits AFTER connection to the Water If the circuit includes OsmaGold fittings, as Flow Controller. OsmaGold Pressure-Tester. The pressure test should be dated and recorded as a permanent record (see pages 23-24). it may when Chipboard Modules are used OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Design Procedures 9 UNDERFLOOR HEATING Design Procedures General Considerations ■ 5 Water Flow Control SMALL PROJECTS Or: so that it cannot operate if there is no In small projects, covering areas less than It is recommended that the supply to the heated water in the Primary. The pipe 20m2, either Single Port Manifold and Water Mixing Controller should be taken providing water to the Controller should Control Pack, or Water Mixing Control can from the heating Primary, either before have sufficient capacity to supply the be used. or after any timed Diverter Valve, which quantity of heat required by the section of controls the supply to radiators for UFH attached to it. AREAS GREATER THAN 20m2 In larger projects a manifold should be used up to a maximum of four ports. example, as required. The electrical supply to the Water Mixing Controller can be timed or otherwise, as required, although in general the wiring should be arranged 6 Room Temperature Control Either standard or programmable room (generally the Boiler Live) is fed through the thermostats may be used (purchased room thermostat to the controller. separately). In projects having more than one temperature zone, the flow of water into each circuit is controlled by a 2 Wire Actuator on each circuit branch, In small projects, where there is a single zone, the electrical feed that is used to enable/disable the Water Mixing Controller 7 which is opened/closed under the control of its associated room thermostat. The OSMA UH1-M Wiring Centre connects each room thermostat to the appropriate actuator. The operation of any one actuator will turn on the Water Mixing Controller and boiler and initiate the flow of heated water to it. Project Design Once the most appropriate products have Important Notes been selected, a dimensioned design/ Never bend 15mm OsmaGold pipe GENERAL CONSIDERATIONS installation drawing should be produced. A more tightly than a radius of 120mm. Response times: Design Planning Grid is produced on page If you have bent the pipe too tightly and Setting pipe within a 65-75mm screed 30 of this brochure to help with it has kinked the pipe needs to will form an underfloor heating system project design. be replaced with quite high thermal mass. From The drawing should show where each Always cut OsmaGold pipe using an cold, it will have to warm up the mass floor component and the Water Mixing OsmaGold cutter or sharp secateurs. of the screed before the top surface Controller is to be sited. This will also Never use a saw blade can begin to radiate. Once warm, assist in producing a full schedule of the materials required. INSTALLATION PROCEDURES Generally, products should be installed in the following stages: 1. Clear the space to be heated Always use pipe inserts whenever a joint is formed Never use joints in pipe if pipe is going to be placed in screed it will continue to produce heat for several hours even after the boiler has turned off Underfloor heating in a timber floor has a smaller thermal mass to warm up Always allow screeds to dry naturally. before it starts to work but it will cool Don’t use UFH pipe as a way of down more quickly after the boiler has speeding up the drying process turned off 2. Install Floor Components and Pipe Additives: 3. Conduct pressure-test Generally, the additives that the boiler 4. Install Water Mixing Controls and or radiator manufacturers specify will have no effect on the OsmaGold pipe. connect circuits If in doubt contact OSMA UFH 5. Connect up Electrics 6. Commission 10 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING General Considerations Project Design continued HEAT LOSS CALCULATION To calculate the actual heat losses from a room do the following sum: Next, calculate the area (m2) of the exposed Volume of room (m3) x floor space that may be heated. Difference between design internal 2 Area of surface (m ) x Divide total heat required (Watts) by available and external temperatures x Temperature difference between the floor area (m2) to calculate Power required (W/m2) (see example below). U-value equivalent = two sides of the surface (°C) x Air Change Loss (Watts) U-value for the surface = 20 00 mm The U-value equivalent to use is: 3 Surface Loss (Watts) AC / hr Add up the amounts for each surface 1.0 0.33 Bedrooms Total Surface Loss (Watts) 1.5 0.50 Living Rooms Add to this figure the energy needed to 2.0 0.66 Bathrooms Next sum together Surface Loss and Air Change Loss = 80 0m m 2400mm 1200mm Typical for 1200mm heat any incoming cold air as follows: U-value mm 0 00 mm 00 12 Total Loss (Watts) Example INPUT DATA Room STUDY 2 SURFACE U-value Exterior Walls 0.30 Floor Area 6.00 m Windows & Doors 2.30 Height 2.40 m2 Internal Walls 0.90 Exterior Wall 9.60 m 2 Ceiling/Roof 0.50 Interior Wall 12.00 m2 Air Changes per Hour 1.50 2.40 2 Glazing m DESIRED ROOM TEMPERATURE 20 °C ROOM TEMPERATURE SUBTRACT OUTSIDE TEMPERATURE -2 °C AVERAGE INTERNAL ROOM TEMP EQUALS TEMPERATURE DIFFERENCE 20 °C 15 °C 5 °C SUBTRACT EQUALS 22 °C INTERIOR ROOM DIFFERENCE EXTERNAL WALL Area (Minus) Glazing 9.60 m2 U-value MULTIPLY 0.30 Temp Diff MULTIPLY 22 Watts Loss °C EQUALS °C EQUALS °C EQUALS °C EQUALS 63.36 WINDOW & DOOR Area 2.40 U-value m2 MULTIPLY 2.30 Temp Diff MULTIPLY 22 Watts Loss 121.44 INTERNAL WALL U-value Area 12.00 m2 MULTIPLY 0.90 Temp Diff MULTIPLY 5 Watts Loss 54.00 CEILING / ROOF Area 6.00 U-value m2 MULTIPLY Volume 14.40 m3 MULTIPLY 0.50 Temp Diff MULTIPLY AIR CHANGE LOSSES Temp Diff MULTIPLY 22 °C 22 Watts Loss Per Hour 0.50 66.00 Watts Loss EQUALS TOTAL LOSSES 158.40 463.20 DIVIDE BY USABLE AREA 6 EQUALS TOTAL REQUIRED OUTPUT W/m 2 (USEABLE AREA ONLY) 77.20 This figure may now be checked against the Power Output tables on page 8 OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Design Procedures . General Considerations 11 UNDERFLOOR HEATING Product Range Screed Floors 25UH050 15UH153 15UH196 15UH230 15UH323 15UH400 PART CODE PACK QUANTITY 1200 x 600 x 50mm Plain Insulation 25UH050 1 25m x 150mm Multi Height Edge Expansion Foam 15UH153 8 1500 x 800mm System Plate 15UH196 18 Screw Clips (Bag of 50) 15UH233 1 Staples for 15mm OsmaGold Pipe (Box of 300) 15UH230 1 Staple Gun 15UH323 1 Insulation Joint Tape 15UH400 1 OSMA Plate Clips (Pack of 25) 15UH234 1 OSMA Plate Tack Clips (Pack of 25) 15UH235 1 PART CODE PACK QUANTITY 1200 x 340 x 50mm Straight Joist Panel 30UH059 20 1200 x 600 x 50mm Straight Batten Panel 25UH053 5 1200 x 340 x 50mm (3) Loop Return Panel 25UH056 10 1200 x 50 x 50mm Plastic ‘L’ Bracket 15UH700 30 PART CODE PACK QUANTITY 15mm x 50m Coil 15HC160 1 15mm x 100m Coil 15HC180 1 15mm x 15mm Straight Connector 15HC510 5 Branch Tee 15 x 15 x 15mm 15HC542 5 Elbow 90˚ 15mm 15HC530 10 Blanking Caps 15mm 15HC740 10 15UH235 Floating/Batten/Joisted Floor 30UH059 25UH053 25UH056 15UH700 OsmaGold Pipe & Fittings* 15HC160 15HC180 15HC542 * OsmaGold Pipe & Fittings are available from your local OsmaGold stockist 15HC530 15HC740 15HC510 12 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Product Range Single Room Controls 48UH585 PART CODE PACK QUANTITY 1-2 Circuit Control Pack (For Connection to Heating Primary) 48UH585 1 1-2 Circuit Control Pack (For Connection to Radiator Branch) 48UH550 1 PART CODE PACK QUANTITY Manifold Mixing Unit (inc. Pump) 48UH580 1 2 Port Manifold 67UH872 1 3 Port Manifold 67UH873 1 4 Port Manifold 67UH874 1 Port Thermometer 47UH888 1 1" Isolation Ball Valve 47UH585 2 2 Wire Actuator (240V) 52UH802 1 Wiring Centre UH1-M 1 Programmable LCD Thermostat (240V) PRT-M 1 48UH550 System Controls 48UH580 67UH874 47UH888 47UH585 Programmable LCD Thermostat with Domestic Hot Water Timer (240V) 52UH802 PRT/HW-M 1 UH1-M PRT-M PRT/HW-M Accessories 15UH236 15UH305 15UH239 47UH555 PART CODE PACK QUANTITY Pipe Clamps 15UH236 2 Curved Pipe Supports 15UH239 2 Y Connectors for 48UH550 47UH550 2 1/2" Isolation Ball Valve for 48UH550 47UH555 2 Circular Saw Blade 15UH305 1 OSMA Infrared Thermometer 15UH500 1 OSMA Installation/Service Pack 15UH691 1 OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Product Range 13 UNDERFLOOR HEATING For Screeded Floors Basic Products For Screeded Floors Supplied as: Part Number either: ❚ OSMA Screw Clips 15UH233 option Screw Clip Handle 15UH300 or: ❚ OSMA Staples with Staple Gun 15UH230 15UH323 Also required: ❚ Edge Insulation Multi-Height 25m x 125mm 15UH153 ❚ OSMA 15mm Heating Pipe (OsmaGold) see page 12 ❚ Control Unit, Manifold and Room Thermostat or Single Room Controller B A see page 13 ❚ Sand/cement screed – ❚ Insulation – D C E Procedure 1 Ensure flat and level sub-floor. 2 Place edge insulation around the perimeter of the room (see A). 3 Lay plain insulation, with staggered joints, to cover the required area Recommendation: tape joints between 5 Feed the pipe from the centre of laid (so that, if the pipe is damaged the coil. DO NOT REMOVE THE during screeding, any fault can be PACKAGING FROM THE PIPE COIL. detected immediately and rectified). insulation panels to prevent ingress of screed (see C). 6 Secure the pipe to the insulation in accordance with the layout design, 4 Mark out proposed pipe layout on the surface of the insulation panels using Staples or Screw Clips as appropriate (see above). 200mm in from the wall. Recommendation: follow a serpentine pattern, with pipe at 200mm centres, preferably running in the longest direction of the room (see D). Alternatively, follow a spiral pattern at 14 6 At point below where the Water Mixing Controller is to be installed, use Curved Pipe Supports and Pipe Clamps to hold the pipe neatly in place. ❚ Insulation type and thickness should be chosen to satisfy Part L Building Regulations ❚ Staples or Screw Clips to secure pipe to insulation. Use Staples for 7 Once the pipe is installed, pressure 200mm centres. This will put less force test PRIOR to screeding. Keep pipe onto the staples (see page 16, image F). under pressure, while screed is being SALES AND TECHNICAL ENQUIRIES 01392 444122 Requirements FAX 01392 444135 rigid insulation, Screw Clips for soft insulation EMAIL [email protected] UNDERFLOOR HEATING For Screeded Floors System Plates Supplied as: Part Number Individual OSMA System Plates: – 1500 x 800mm = 1.2m2 15UH196 Also required: ❚ Edge Insulation Multi-Height 25m x 125mm 15UH153 ❚ OSMA 15mm Heating Pipe (OsmaGold) see page 12 ❚ Control Unit, Manifold and Room Thermostat or Single Room Controller A see page 13 ❚ Sand/cement screed – ❚ Building adhesive – C B Procedure D E 1 Ensure flat and level sub-floor. A B C D1 2 Place edge insulation around the perimeter of the room (see A). D2 E F G1 3 Lay plain insulation over the sub-floor. 4 Position first System Plate so that the G2 H square corner of the plate with a single nodule is placed into the corner of the room (see B). 5 Lay and fix subsequent plates in the same orientation, locking neighbouring 7 Once the System Plates are in place, plates together by overlapping one fix them down locally to the top of the row of castellations (see C). insulation, in each corner and in the NOTE: Locking the Plates together centre of the room, using either Plate prevents movement and ingress of Anchor Clips 15UH234 or Plate Tacks screed between joints. 15UH235, as this helps to keep the 6 Follow the laying sequence guide above to minimise cutting & wastage F System Plates from lifting after the heating pipe has been inserted (see F). (see D). OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Basic Products . System Plates 15 UNDERFLOOR HEATING For Screeded Floors System Plates continued 8 Install the heating pipe in a spiral pattern F G at centres to achieve required output (usually 200mm centres is adequate). Initially install pipe at 400mm centres into the centre of the room, then reverse out to achieve overall pipe layout at 200mm centres (see F). 9 Along the straight runs, pipe may be unrolled from a standing position (see G). 10 Where a bend or loop is required, insert the pipe carefully between nodules (see H). H I J K IMPORTANT: Do NOT damage System Plate nodules or kink the pipe. L N M 11 The multiplicity of the Plate castellations O 13 If a liquid screed is to be used, use means 90° bends, loops and offsets can 15mm pipe off-cuts to hold down the be easily created. Where a loop edge insulation gaiter (see P). is required (at the centre of a room for P 14 The installed heating circuit is now ready example), the diameter should be min. for the screed. Within the System Plates, 300mm to relieve pipe stress the pipe is well protected from foot traffic (see H, I, J & K). & evenly distributed loads (see Q). 11 Where the UFH pipework converges at the manifold, the pipe may be run off the Q Plate and screw-fixed using Screw Clips Accessory Part No: 15UH233 x 50, Curved Pipe Supports 15UH239 x 2 & Pipe Clamps 15UH236 x 2 can also be used to protect and secure pipe against the wall as the pipe exits the Requirements screed (see L, M, N & O). ❚ Insulation type and thickness should 12 Once the pipe is installed, pressure test be chosen to satisfy Part L Building PRIOR to and DURING screeding. 16 SALES AND TECHNICAL ENQUIRIES 01392 444122 Regulations FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING For Timber Floors Timber Joist Products Supplied as: Part Number OSMA Batten/Joist Panels (50mm insulation – pre-cut channels): 1200 x 340mm 30UH059 OSMA End Panels: (50mm insulation – pre-cut channels): 1200 x 340mm = 0.41m2 [approx.] 25UH056 Plastic ‘L’ Brackets [OR (for installation from below) small battens] 15UH700 Also required: A ❚ OSMA Heating Pipe (OsmaGold) see page 12 ❚ Control Unit, Manifold and Room Thermostat or Single Room Controller see page 13 B C Procedure 1 Measure and cut the ‘L’ Brackets to fit. 2 Nail ‘L’ Brackets to the inside of the joists. Position so that the top vertical edge of the Brackets is flush with the top of the joists (see A). NOTE: When on a suspended floor, lay some boards to stand on. 3 Lay the pre-cut Insulation Panels and End Panels onto the Brackets. Take care not to stand on the panels (see B). 4 Notch the joists as necessary to provide pipe route from bay to bay (see C). 5 Lay pipe by pressing down carefully into the pre-cut grooves. Again, take care not to stand on the panels (see D). 6 Pressure test pipe when layout is complete. 7 Chipboard or solid floor may now be laid (see E). Requirements ❚ When working on suspended floors, always follow required safety D procedures, in accordance with Safety at Work Act, and use necessary safety E equipment NOTE: ❚ Notches must be cut in accordance with building regulation requirements ❚ Do NOT cut notches into the top of a manufactured I beam OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating System Plates . Timber Joist Products 17 UNDERFLOOR HEATING For Timber Floors System FloatingPlates Floor Products Supplied as: Part Number OSMA Floating Floor Panel (50mm insulation – pre-cut channels): 1200 x 600mm = 0.72m2 25UH053 OSMA End Panel: (50mm insulation – pre-cut channels): 1200 x 340mm = 0.41m2 [approx.] 25UH056 Also required: ❚ OSMA Heating Pipe (OsmaGold) see page 12 ❚ Control Unit, Manifold and Room Thermostat or Single Room Controller see page 13 B A C D Procedure 1 Lay loop return End Panels along each 6 Installed within the pre-cut grooves, the pipe is well protected from foot traffic of the ‘short’ ends of the room (see A). and evenly distributed loads (see G). 2 Lay Floating Floor Panels between the loop return End Panels, ensuring the 7 Pressure test pipe when layout is complete, prior to installing floor deck. pre-cut channel line up (see B). 3 Follow the laying sequence above to minimise cutting and wastage. Use plain F E insulation panels in areas that will fall under fixtures/fittings (see C). 4 Once all the panels are in place, install pipe by pressing carefully into pre-cut grooves (see D). G 5 Ensure the pipe is held securely when fitting into the loop return End Panels. Along the straight lengths, the pipe can be installed standing up, using a press of the foot (see E & F). 18 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING For Timber Floors Timber Batten Floor Products Supplied as: Part Number OSMA Batten/Joist Panels (50mm insulation – pre-cut channels): 1200 x 340mm 30UH059 OSMA End Panels (50mm insulation – pre-cut channels): 1200 x 340mm = 0.41m2 [approx.] 25UH056 Also required: ❚ OSMA Heating Pipe (OsmaGold) see page 12 ❚ Control Unit, Manifold and Room Thermostat or Single Room Controller see page 13 ❚ 50 x 50mm timber battens A B C D E F Procedure 1 Lay 50mm batten against the wall. 2 Lay a loop return end panel (see A) at each end of the batten space. 3 Fill Batten/Joist Panels to complete the first row of insulation against the edge batten (see B). 4 Butt the next batten up against the side of the first row of insulation (see C). 8 Install pipe within the pre-cut grooves ❚ OSMA UHF Batten/Joist Floor Panels (see F). 9 Pressure test pipe when layout is complete, prior to installing T&G floor deck. If the floor finish is to be a wooden floor: It may be possible to lay this directly over the UFH Panels, omitting T&G deck (Consult supplier of floor deck). 5 Then continue across the floor, with battens between panels of insulation (see D). Requirements For ceramic or stone floor finishes: 30UH059, these have been designed to provide a UFH system between 50 x 50mm battens at 400mm centres ❚ Circular Saw Blade 15UH305. Foiled panels can be cut using a handsaw and sharp knife. However, we recommend use of a circular saw with this specially designed blade for cutting through insulation and foil Battened floor construction with T&G plywood deck will provide suitably rigid If secret nailed floor finish is to be installed: 6 Nail or screw-fix battens securely to the base (Consult floor finish supplier). G H sub-floor (optional). 7 Once all Insulation Panels are in place, notch battens to provide pipe route from bay to bay (see E). OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Floating Floor Products . Timber Batten Floor Products 19 UNDERFLOOR HEATING Mixing Control Units Mixing Control Units Individual items 2–4 Port Manifold (Part No’s: 67UH872 – 67UH874) (available from OSMA UFH) 25mm internal diameter plated brass 2-Wire Actuator body with integrated regulation valves. (Part No. 52UH802) Manifold distribution arms form 2–4 heating circuits 2 x connections to the rest of the system with 1” union nuts (female flat connection for 1” Isolation Ball Valves (available from OSMA UFH), or for connecting an OSMA UFH Control Pack Integral air release and filling/draining point Port Thermometer Each port equipped with a “Euroconus” (Part No. 47UH888) pipe adaptor to receive 15mm OsmaGold pipe Supplied complete with wall brackets and screw fixings Flow distribution arm Regulating valves to regulate and isolate the water flow for each circuit. Return distribution arm Control valves for operation by 2-Wire Actuators (available from OSMA UFH). Clamp-on Port Thermometer Control Pack (Incl. Pump) (Part No: 48UH580) (Part No. 47UH890) Water mixing valve for use with UFH systems connected to a boiler that produces water at temperatures higher than 65°C. The Control Pack simply screws into the OSMA UFH Manifold distribution arms. The Control Pack incorporates: 2 x 1” female flat connections to the rest of the system (incl. Gaskets) 1” Isolation Ball Valve Secondary circulator suitable to serve (Part No. 47UH585) up to 4 x 100m heating circuits A water mixing valve that achieves faster warm-up times by not mixing flow water until the desired flow temperature has been reached 20 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Mixing Control Units System Mixing Control Plates Units continued A B C Procedure A Assembly of Heating Arms Procedure B Mixing Unit 1 Lightly screw a plastic pipe adaptor 4 Screw the Control Pack onto the (self-sealing) onto each of the fitting Manifold arms using the gaskets adaptors. These are compression supplied. This produces a watertight fittings designed to connect 15mm seal (see H). OsmaGold pipe (see A). D 5 Attach 1” Isolation Ball Valves directly If Port Thermometers (47UH888) are to the Control Pack OR, if a Control being used: Pack is not required, attach the Isolating Screw into place on the return arm and Valves direct to the Manifold arms. This seal using PTFE tape or liquid sealant, allows for complete isolation of the and refit the plastic pipe adaptors (see B). Manifold. 2 The wall brackets supplied allow for the creation of a staggered manifold assembly. Position the flow arm on the top (as shown) (see C). 3 Remove the blue wheel heads from the E NOTE: – All joints need checking prior to filling and testing on site for their integrity. – Temperature Controller and Temperature Gauge are pre-installed (see G). F manifold return and screw on the actuator base, then carefully attach the Requirements 2-Wire Actuators 52UH802 (see D and ❚ A standard by-pass should be E). installed just below the flow and NOTES: return – If the Manifold has been designed to provide control for one heating zone only, a motorised valve can be installed on the feed to the Manifold instead of fitting an G H Actuator to each individual circuit. 15mm joiners can be supplied. – Each manifold arm is equipped with a pre-installed dual purpose 1/2” air releasing /draining valve (see F). – The valve rotates so that in the ‘up’ position (as shown), air can be released when filling and commissioning the UFH system. When in the ‘down’ position, water can be drained out of the Manifold. OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Mixing Control Units 21 UNDERFLOOR HEATING Mixing Control Units Mixing Control Units continued 2-WIRE ACTUATOR (Part No: 52UH802) Normally closed 230V Actuator for use with OSMA UFH Self-Assembly Manifold No special mounting tools required. Simply screw onto return arm control valves 2-Wire Actuators for use with UH1-M wiring centre. (See below for wiring configuration). Wiring Arrangement 22 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING Pressure Testing System Pressure Plates Testing Procedure Once the UFH pipe has been installed, pressure test each circuit to verify the integrity of the pipework and connections. Preparation Testing After the test 1 Ensure the circuit is complete. Use 4 Open both valves on the unit fully and 9 Release the return line valve, blanking caps or blanking plugs to gently pump water into the circuit using allowing the surplus water back into blank off any open ends. the hand pump (replenishing the water the reservoir. 2 Load water into the tank of the pressure testing unit and connect the circuit flow tube end to the outlet connector of the tank. 3 Connect the circuit return tube end to the return connector on the tank where fitted, or via a controllable valve to a bucket or similar. in the tank if necessary) until a steady 10 Disconnect the flow and return tube flow WITHOUT ANY AIR BUBBLES is ends from the Manifold, and seen to be flowing through the circuit reconnect to the relevant ports. back into the tank. 5 At this stage, close the return line valve. Then manipulate the pump SLOWLY whilst monitoring the pressure gauge. 6 Continue pumping until a pressure of some 18 bar shows on the pressure gauge. At this stage, stop pumping and close the flow valve. This pressure should be maintained for 30 minutes. 7 After 30 minutes, check the pipework and fittings for evidence of a leak: – If there is no sign of leakage in any of the joints, and – there is no reduction in pressure Requirements ❚ Hydraulic Pressure Tester - available from most hire shops ❚ 15mm straight connections for attaching OsmaGold pipe to pressure the circuit can be presumed to be tester secure. NOTE: The procedure explained 8 Complete the pressure test record (see page 24), not forgetting to enter applies to a “Rothenburg” manual pressure-testing unit the time and date. OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Mixing Control Units . Wiring Arrangements . Pressure Testing 23 UNDERFLOOR HEATING Pressure Testing Pressure Test Record Tested by: Date: Project: Project Reference: Floor 24 Zone SALES AND TECHNICAL ENQUIRIES 01392 444122 Circuit Test Notes FAX 01392 444135 Pass Signed EMAIL [email protected] UNDERFLOOR HEATING Design Planner System Design Planner Plates Detailed planning and design of each For guidance, we provide an example UFH project is essential in order for work below. on site to proceed efficiently. This also helps scheduling of the components and materials required, and reliable estimation When creating a design, we recommend that you use a grid with a scale of each square = 50 x 50mm. of costs. 2500mm 4000mm 1000mm 2500mm OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Pressure Testing . Design Planner 25 UNDERFLOOR HEATING Notes 26 SALES AND TECHNICAL ENQUIRIES 01392 444122 FAX 01392 444135 EMAIL [email protected] UNDERFLOOR HEATING General Information ■ How to Order ■ Technical Advice General Information and Ordering Health and Safety Supply OSMA Underfloor Heating. Goods are The relevant provisions of the following All OSMA systems described in this sold subject to Company conditions of legislation should be adhered to on site: Design and Installation Guide are sale. supplied through a nationwide network It is the responsibility of the Installer/ of Merchant Distributors. For details of Customer to ensure that the system is your nearest stockist, contact OSMA correctly installed and that the Underfloor Heating. boiler/heat source has sufficient Health and Safety At Work Act 1974 Ordering capability to satisfy the demand of the Management of Health and Safety To order, be ready to quote the Product UFH system, or conversely is not overly At Work Regulations 1999 Name and relevant Part Number, powerful. together with quantities required. Part numbers are clearly indicated in For sales enquiries, or to place an order bold type throughout this Design and Please contact Installation Guide [EXAMPLE: 15UH110] OSMA Underfloor Heating: Conditions of sale Sales /Orders The Company will not accept Tel: 01392 444122 Construction (Design and Management) Regulations 1994 Control of Substances Hazardous to Health Regulations 1988 Manual Handling Operations Regulations 1992 References Reference should be made to: Building Regulations (England and Wales): Approved Document ‘L’ (Thermal) Building Regulations (England and Wales): Approved Document ‘E’ (Acoustic) responsibility for the malfunction of any installation not designed by OSMA Underfloor Heating, which also includes Fax: 01392 444135 Email: [email protected] using components not supplied by Technical Advice and Assistance OSMA Underfloor Heating systems are Services include: For prompt assistance, contact backed by a comprehensive technical CAD product and application details OSMA Underfloor Heating: advisory service. This is available to on disk Technical Enquiries provide expert assistance at every stage Computer aided project design, for of a project, from planning and product Tel: 01392 444122 more complex projects for which a selection to installation and maintenance. charge is payable Fax: 01392 444135 Email: [email protected] Call-off service for efficient product scheduling OSMA UFH Design and Installation Guide 2006 LITERATURE 01249 766333 Underfloor Heating Notes . Information & Ordering . Technical Advice 27 Underfloor Heating Available Through Merchants Design and Installation Guide For screeded and timber floors This brochure provides detailed guidance on the design and installation of OSMA Underfloor Heating systems available through merchants. These systems are primarily designed for use in residential applications. This OSMA UFH product range: Is designed for time-saving, easy installation – without requiring special tools or experience Provides consistent, controllable heat output and performance Enables achievement of a high quality result every time OSMA also provide design and production of bespoke systems to meet specific application requirements or to suit specialised construction projects. These include acoustic and sprung floors, specialist screeds, high strength floating floors, and industrial ISO 9001:2000 floors – or for multiple unit projects requiring large numbers of identical installations (housing or flats). OSMA UFH technology can also be used for cooling. For information, contact OSMA Underfloor Heating Apple Lane Sidmouth Road Exeter Devon EX2 5GL Tel: 01392 444122 Fax: 01392 444135 Email: [email protected] The range is supplied by OSMA Underfloor Heating which is the trading name of ThermoBoard Limited. OSMA is a registered trade mark of Wavin Plastics Ltd and is used by ThermoBoard Limited under licence. ThermoBoard Limited operates a programme of continual 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. www.wavin.co.uk UF417 OSMA Underfloor Heating.
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