View source for Installation Instructions for the Data Split HIU

==Explanation of symbols and abbreviations==

===Symbols===

{{IMGC|Symbols.jpg|600px}}

===Abbreviations===
{{IMGC|Abbreviations.jpg|450px}}

==Introduction==

The DATA SPLIT Hydraulic Interface Unit (HIU) combines the power and control of the DATA HIU, with some useful practical features:-

* The expansion vessel and safety relief valve can be positioned remote from the HIU in a more convenient position for the end user to access the CH pressure gauge and filling loop.
* The HIU weighs considerably less than most twin plate HIU's due to a structural Expanded Polypropylene (EPP) casing, and the omission of the expansion vessel, safety relief valve and associated pipework.
* The HIU is mounted on to our standard Pre-plumbing bracket, making it a very quick and easy fit, but also opening up the possibility of fitting fully indirect or our DIGI direct CH HIU's to the same network.
* The Pre-plumbing bracket allows for the pipework to be routed straight down or up the back of the HIU, or a mixture of both, making it extremely versatile.

The control system and performance is exactly the same as the DATA HIU.  Independent testing has proved how good the DATA HIU performs, and the DATA SPLIT HIU performs equally as well. 

Within the casing are all the components required for a typical property connected to a district network, these include temperature sensors and pressure independent control valves for extremely accurate DHW and CH control. A differential pressure control valve can be fitted to the primary circuit if it is anticipated that the differential pressure will rise above 2.5 Bar, alternatively a landlord security valve may be fitted to allow remote isolation of the HIU. The Heat Meter display is routed to a simple opening in the casing or for mounting locally to the HIU on the wall.

In this manual, attention is paid to the installation of the HIU and the associated applicable regulations. These must be followed for correct and trouble-free operation of the HIU. In addition, you will find general technical data and information about maintenance, any faults and possible causes. This document must be stored with the HIU.

'''The heating installation must be equipped with a correctly sized expansion vessel and safety relief valve fitted between the HIU and any isolation valve on the heating circuit.  It is also advisable to fit a filling loop and pressure gauge to the heating system, in a location convenient for the end user to access and top-up the central heating system.  Refer to the chapter on "Installation Requirements" for more information. Contact Thermal Integration for more information on parts availability and advice on system safety.'''

==Overview of Components and Connections==
{{IMGC|DATA SPLIT Parts ID.jpg|600}}


<html><table align="center"><tr><td width="350" align="left"></html>
1 Insulating Casing<br>
2 Electronics 24V <small>(Pt. 70HSF53051)</small><br>
3 Status LED<br>
4 Heat Exchanger (CH)<br>
5 CH primary return temperature sensor <small>(Pt. 70HSF53052)</small><br>
6 Automatic Air Vent<br>
7 Electronics 230V <small>(Pt. 70HSF53051)</small><br>
8 Central heating control valve <small>(Pt. No. 70HSF51495)</small><br>
9 DHW primary return temperature sensor <small>(Pt. 70HSF52727)</small><br>
10 DHW control valve <small>(Pt. 70HSF51495)</small><br>
11 Flow sensor <small>(Pt. 70HSF50274)</small><br>
<html></td><td width="350" align="left"></html>
12 Heat exchanger (DHW)<br>
13 Heat meter sensor pocket<br>
14 Spare sensor pocket <small>(for DPCV)</small><br>
15 Heat meter spool piece<br>
16 Primary strainer <small>(Pt. 70HSF51891)</small><br>
17 CH pump <small>(Pt. 70HSF53063)</small><br>
18 Temperature and pressure sensor CH supply <small>(Pt. 70HSF53056)</small><br>
19 Spare spool piece <small>(DPCV or Landlord Security Valve)</small><br>
20 DHW flow temperature sensor <small>(Pt. 70HSF52727)</small><br>
21 CH strainer <small>(Pt. 70HSF51890)</small><br>
22 Primary flow temperature sensor <small>(Pt. 70HSF52727)</small><br>
<html></td></tr></table></html>

==Available Options==

The unit has several options available depending on requirements. The basic unit can be equipped with any combination of the following:

*Option A1: Spool piece, used when neither option B or C are required.
*Option A2: Landlord security valve, allows the landlord to remotely isolate the unit from the district heating network if required.
*Option A3: Differential pressure control valve, to balance differential pressures between the primary flow and return. Only required where the differential pressure exceeds 250kPa. (Max 450kPa)
*Option B: Flushing Bypass for connecting to the primary flow and return pipework (External to the unit)
*Option C: External DHW recirculation unit, to provide constant circulation of DHW throughout the property in order to allow quicker response times at the tap where extended pipe runs are unavoidable.  Note: The HIU must be set to 'Comfort' Mode by the installer, when this option is fitted.
*Option D: Heat Meter.  It is possible to fit most brands of heat meter into the HIU, contact Thermal Integration for further information.

{{IMGC|SPLIT_Options.jpg|600}}

==Dimensions==

The Pre-Plumbing bracket allows the unit to be spaced from the wall, from 50 to 75mm.

{{IMGC|SPLIT dimensions.jpg|600}}

==Technical Data==
{{:DATA SPLIT Technical data}}

==Description==
The HIU is for use in properties connected to a district heating system using a centralised boiler and is suitable for both central heating and domestic hot water.  Each hydraulic circuit to which the HIU is connected, must meet minimum water quality standards as stated in document "Requirements on water quality for Heat Interface Units for District Heating systems".

Please keep the following conditions in mind during installation:

*The unit must be installed in a frost free area.
*The unit must not be exposed to direct sunlight.
*Ambient temperature should be between +5&deg;C and +40&deg;C.
*Humidity should be between 10% and 85%.
*The unit must be connected to a fused double pole isolator.
*The unit uses 230 VAC. Use caution when handling. Contact may lead to shock, burns or electrocution.
*Components in the unit and connected to the unit can reach high temperatures. Contact may lead to burns.

===Status Indicator LED===
*'''Green blinking slowly (about 1x per second): HIU is at rest; there is no heat demand and all control valves are closed.'''
*'''Green blinking fast (about 2x per second): HIU is in Heating mode; there is a heat demand and the control valve is open.'''
*'''Blue blinking: HIU is in Hot water mode; there is a water draw-off and the control valve is open.'''
*'''Red blinking: Error'''
*'''White continuous (only for engineers): HIU is in service mode'''
*'''No LED: HIU is switched off'''

==Operation==
The HIU is equipped with two heat exchangers, the right hand heat exchanger transfers the heat from the district heating system to the DHW circuit and the left hand heat exchanger transfers the heat from the district heating system to the CH circuit.  These heat exchangers ensure hydraulic separation between the property and the district heating network. The hot water in the district heating network does not come into contact with the hot water or heating circuit of the property. Heat is transferred from the district heating network via the heat exchangers to the domestic hot water system and central heating system.

===Central heating===
The temperature of the property's heating system is controlled automatically by the HIU.  When heating demand finishes, the heating pump will be switched off after a defined pump over-run time (default: 15 minutes).  If there is no heat demand for longer than 24 hours, the pump will be exercised for a brief period of time to prevent sticking.

===Domestic Hot Water===
The electronics within the unit, together with domestic hot water control valve, temperature sensors and flow sensor, regulate the temperature of the hot water to it's set point (As Standard 55&deg;C).  The HIU has a very low switching point, recognising DHW flow rates as low as 1 l/min.

Each HIU has two domestic hot water keep hot modes, Eco or Comfort mode. These can only be selected during commissioning or by a trained engineer.

The default setting is Eco mode, and this can be specified to run for 0 minutes (which turns the feature off all together), 15, 30, 60 or 120 minutes after the last hot water draw off. In Eco mode the heat exchanger is kept to a specified temperature (between 25 and 60&deg;C) for the selected period of time and after this period of inactivity has elapsed the control valve closes completely and the temperature in the domestic hot water circuit is allowed to drop through natural dissipation to minimize energy consumption. If a hot water draw off is made any time throughout the Eco mode function the unit will deliver hot water as usual and the Eco mode function will begin counting down for the selected time once again.
In Comfort mode the heat exchanger is continuously supplied with a trickle of primary water for quicker hot water delivery, however energy consumption will be slightly higher than if the unit was set in Eco mode.

To prevent legionella from growing the heat exchanger is heated to 60&deg;C for at least 60 minutes every 24 hours. (it is not possible to specify the time at which this occurs) 

[[File:Caution.jpg|150px]]

'''The hot water temperature is regulated to temperatures as high as 60&deg;C. If there is a power outage during DHW draw off, units not fitted with a landlord security valve will stop regulating the hot water temperature. This may lead to a hot water temperature that is higher or lower than the setpoint. Hot water can cause burns.'''

===Priority Switching===
The unit is fitted with domestic hot water priority switching. When hot water is drawn off, the central heating control valve will close,
diverting all primary flow to heat the domestic hot water circuit. Primary flow to the central heating is cut off during hot water delivery.
If there is a heat demand, primary flow to the central heating is resumed immediately after the hot water draw off has finished.

==Adjusting Settings==
The DATA SPLIT requires connection to either a PC running the commissioning software, or by the use of an iHIU Controller, in order to adjust settings.

End users cannot adjust settings, unless an iHIU Controller is used.


===PC Software===

The software is made freely available, along with training, to registered commissioning engineers. Please contact Thermal Integration for further information.

The software allows one to adjust the following settings:

{| class="wikitable"
|-
! Setting !! Options !! Default
|-
| Domestic Hot Water Temperature || 45&deg;C to 60&deg;C || 50&deg;C
|-
| Primary Differential Pressure || Auto or Manual from 0.3 to 2.0 bar || Auto
|-
| Warmup Boost Flow Rate || 8 to 20 l/min || 20 l/min
|-
| Return Temperature Limit || Disabled or Enabled from 35&deg;C to 65&deg;C || Enabled 50&deg;C
|-
| Maximum Central Heating Temperature || 30&deg;C to 80&deg;C || 80&deg;C
|-
| Central Heating Pump Timeout || 0 to 30 minutes || 15 minutes
|}

===iHIU Controller===

The iHIU Controller is a miniature Linux web server that can be supplied separately to provide more advanced control and monitoring of the Data HIU. The controller is typically mounted within the casing of the HIU, with an option for a display on the front of the HIU.

The controller provides a WiFi zone, and can log onto existing networks through either WiFi or Ethernet to gain access to the internet. The HIU can then be controlled directly from other devices on the local network, such as smartphones. Once connected to the internet the system can provide remote control and monitoring services, as well as many other features, some of which are listed below:

* Browser based cross platform interface that adjusts to screen size
* Allows setting of all the parameters available to the PC software, except via a browser
* Control over central heating as well as other settings via Google Calendar
* Remote commissioning
* Remote fault alarms and message forwarding via email or SMS
* Voice control over services via Android app
* Connection to Energy Saving Trust's Embed Database for free and secure online storage of all system data

==General Plumbing Requirements==

{{:General_Plumbing_Requirements}}

==General Wiring Requirements==

{{:Wiring:_General_Wiring_Requirements}}

==Schematic==
{{:Schematic: Data SPLIT HIU}}

==Wiring Diagrams==

===Power Supply===

The heat interface unit is equipped with a wiring centre that converts the 230 VAC power supply to 24 VDC and powers the CH pump and optional DHW pump. It also houses the main fuse for the unit.

{{IMGC|Power_supply.jpg|600px}}

===Room thermostat connection===
A room thermostat can be connected to the HIU, the HIU will then respond to a heating demand from the room thermostat. The connection of a room thermostat is not mandatory, the HIU is supplied with a coupler plug on the thermostat connection cable which creates a closed contact to simulate a heat demand on the HIU.


[[File:Important Note.jpg|125px]]

The room thermostat must be an on/off thermostat with potential free contacts or a Honeywell round on/off (T87G2014) thermostat with power stealing technology. Thermostats that do not have a potential-free contact must not be fitted.

{{:Wiring: Data HIU with Ethernet Billing}}

==Important Installation Requirements==

[[File:Caution.jpg|150px]]

'''Components in the HIU, pipes and radiators may reach high temperatures. The HIU is designed for heat distribution networks with water temperatures up to 95&deg;C. The pipes and parts in the HIU as well as pipes and radiators in the heating system can also reach this temperature. Contact can lead to burns.'''

===Central Heating===

When installing the HIU, the following conditions '''must''' be observed (see the following diagrams):

1. To guarantee correct operation of the HIU, an appropriate and approved connection bracket must be fitted.

2. The heating installation must be equipped with a correctly sized expansion vessel and safety relief valve fitted between the HIU and any isolation valve on the heating circuit.

3. It is advisable to fit a filling loop and pressure gauge to the heating system, in a location convenient for the end user to access and top up the central heating system.

4. The heating system must be equipped with a WRAS approved over pressure safety relief valve (rated to 3 bar), fitted between the HIU and any isolation valve on the heating circuit.

5. A heating control valve '''must not''' be installed in the heating circuit. The room thermostat should, if used, be connected to the room thermostat cable of the HIU.

6. Before the unit is commissioned, the central heating circuit must be fitted with an automatic bypass valve to maintain a minimal flow rate and regulate pressure across the system. The valve must be installed between the central heating flow and return, noting the direction of flow.  The automatic bypass must be fitted before any isolation valve on the heating circuit.


{{IMGC|Central Heating Isolation.jpg|600}}

'''NOTE''' For optimal energy efficiency and comfort, it is of the utmost importance to hydraulically balance the CH system correctly. For the same purpose it is advisable to design the CH system in such a way that the CH return temperatures are as low as possible.

'''* Artificially softened water must not be used to fill the central heating system'''

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===DHW Recirculation Unit===

The DHW recirculation unit is an available option for fitting external to the HIU. The recirculation system must not contain any isolation valves. Applying valves to the system can cause the pump to overheat due to insufficient flow.

{{IMGC|DHW Recirc Isolation.jpg|600}}

Keep following condition in mind during installation:

*Maximum pressure supplied by the domestic water circuit is 10 bar.
*All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be WRAS approved.

==Service and Inspection==

[[File:Caution.jpg|150px]]

'''Components in the HIU, pipes and radiators may reach high temperatures. The HIU is designed for heat distribution networks with water temperatures up to 95&deg;C. The pipes and parts in the HIU as well as pipes and radiators in the heating system can also reach this temperature. Contact can lead to burns.'''


To ensure the unit functions properly, it is advised to periodically inspect the installation.

Maintenance and repairs should be carried out by recognised personnel only.

* Remove the power from the unit when performing maintenance and/or repairs.
* Connect the flow and return valve from the district heating network.
* Connect the flow and return valve on the unit.
* Check the unit for leaks.
* Check the primary and central heating strainer for debris and clean if necessary.
* Check valves for debris and clean if necessary.
* Check the unit operates satisfactorily in domestic hot water and central heating modes.
* The casing can be cleaned with a damp cloth. Do not use detergents of any kind.


{{IMG|Warning_message.jpg|300px}}


'''The unit uses electrical components (230VAC and 24VDC). These components must stay dry at all times. Contact with these energized components can result in an electrical shock, burn, or electrocution.'''

===Prolonged Absence or Holiday===

Do not switch the unit off during periods of prolonged absence or holiday. To prevent frost damage within the unit or the distribution network, the radiator and shutoff valves MUST remain open. Radiators can be switched to the frost protection position (slightly opened) and/or the room thermostat lowered to a MINIMUM of 10&deg;C. It is recommended to flush all water tapping points and showers for at least 2 minutes after a long period of absence.

==Performance==

===DHW===

The following chart and graphs can be used to check the operation of the HIU and the district heating network to which it is connected.

====DHW Performance Table====

{{IMGC|E8LASx40_DHW_Performance_Chart.jpg|450}}

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====DHW Power Chart for 10-55&deg;C====

{{IMGC|Domestic_Hot_Water_Power_Output_10-55.jpg|600}}

====Primary Return Temperatures for 10-55&deg;C====

{{IMGC|District_Heating_Return_Temperature_10-55.jpg|600}}

====Primary Flow Rates for 10-55&deg;C====

{{IMGC|District_Heating_Flow_Rate_10-55.jpg|590}}

====Primary Pressure Drop for 10-55&deg;C====

{{IMGC|Pressure_Loss_%28Primary%29_10-55.jpg|590}}

====Domestic Hot Water Pressure Drop for 10-55&deg;C====

{{IMGC|Domestic_Hot_Water_Pressure_loss_10-55.jpg|570}}

===Central Heating===
====Central Heating Temperature Curves for 80-50&deg;C====

{{IMGC|STD_DATA_SPLIT_Heating_Temperature_Curves_-_E8LAS_x_40_(rev_1).jpg|550}}

====Central Heating Temperature Curves for 70-40&deg;C====

{{IMGC|STD_Heating_Temperature_Curves_-_E8LAS_x_40_-_70-40_systems_(rev._05).jpg|560}}

====Central Heating Temperature Curves for 60-40&deg;C====

{{IMGC|STD_Heating_Temperature_Curves_-_E8LAS_x_40_-_60-40_systems_(rev._05).jpg|560}}

====Central Heating Temperature Curves for UFH 45-35&deg;C====

{{IMGC|STD_Heating_Temperature_Curves_-_E8LAS_x_40_-_UFH_systems_(rev._05).jpg|560}}

==Installation Set-up==

The following parts and tools will be required for installation of the HIU.


{{IMGC|Installation setup.jpg|650}}



'''The heating installation must be equipped with a correctly sized expansion vessel and safety relief valve fitted between the HIU and any isolation valve on the heating circuit. It is also advisable to fit a filling loop and pressure gauge to the heating system, in a location convenient for the end user to access and top-up the central heating system. Refer to the chapter on "Installation Requirements" for more information.'''

==Stage 1 - Removing the front cover==

The front of the case simply unclips from the rear by holding it either side and pulling firmly.  Fibre washers, case fixings and security caps are contained within the casing of the HIU.

{{IMGC|Case Removal.jpg|600}}

==Stage 2 - Pipe Connections==

{{IMGC|Pipe Connections2.jpg|600}}

==Stage 3 - Mounting the HIU==

{{IMGC|Plumbjig Connection.jpg|550}}

{{IMGC|Plumbjig Connection2.jpg|550}}

==Stage 4 - Installing the Heat Meter==

{{IMGC|SPLIT Fitting Heat Meter.jpg|600}}

{{IMGC|SPLIT Fitting Heat Meter2.jpg|600}}

==Stage 5 - Programmer and Room Thermostat Connection==

The unit can (optionally) be connected to a programmer / room thermostat, to control central heating timing and / or temperature.

{{IMG|Warning_message.jpg|300px}}

Connecting the programmer / room thermostat:
#Locate the brown and white twin cable (600mm Long) at the back of the HIU electronic controller, remove and discard the temporary coupler plug.
#Connect a '''VOLT FREE''' programmer / room thermostat (sold separately) across the brown and white cables.


[[File:Important Note.jpg|125px]]

The room thermostat must be an on/off thermostat with potential free contacts or a Honeywell round on/off (T87G2014) thermostat with power stealing technology. Thermostats that do not have a potential-free contact must not be fitted.

{{IMGC|SPLIT RT Cable.jpg|350}}

==Stage 6 - Venting the Heating System==

It is important that the central heating system within the property is completely bled of air. The HIU is equipped with an automatic air vent, connected to the central heating circuit of the HIU. The automatic air vent has a quick air release function which requires manual operation.

'''Quick venting:'''

1. Vent the central heating system at the radiators.  Start at the lowest point of the central heating system and finish at the highest.  For fast bleeding of the HIU, turn the red cap of the automatic air vent counterclockwise, but do not remove this cap.

2. If necessary, the venting function of the pump can also be used to aid bleeding (see chapter "Setting the pump").

3. Continue venting the entire central heating system and the HIU until the entire system has been completely bled.

4. Make sure that all the vents on the radiators are closed tight and turn the red cap of the automatic air vent on the HIU, clockwise until finger tight.


[[File:Important Note.jpg|125px]]

Do not remove the automatic air vent cap while the HIU is in operation.  Ensure dirt is prevented from entering the automatic air vent nipple, as it may cause a blockage.  Ensure that it does not come into contact with chlorine products (≥ 250 ppm) and that steps are taken to eliminate water hammer in the central heating system.

{{IMGC|SPLIT AAV.jpg|400}}

==Stage 7 - Commissioning==

Follow the steps below for connecting and commissioning the HIU.

{{IMG|Warning_message.jpg|300px}}

1. Close all isolation valves in the property.

2. Check all coupling nuts for leakage. (nuts may become loose during transport)

3. Make sure the electronics are securely mounted into the rear casing and ensure cables will not foul the front casing when fitted.

4. Connect the units power cables (A) to the power outlet.
*Blue cable: N (Neutral)
*Brown cable: L (Live)
*Green/yellow cable: E (Earth) [[File:Earth Symbol.jpg|15px]]

5. Slowly open the filling loop valves to pressurise the unit and check for leakage.

6. Switch on the power supply to the unit. The LED should show a green blinking light (C).

7. Slowly open the district heating flow valve (D) and check for leakage.

8. Slowly open the district heating return valve (E) and check for leakage.

9. Fully open all (thermostatic) radiator valves in the house.

10. Fill and bleed the central heating system of the house.  Start at the lowest and finish at the highest radiator or venting point (see chapter "Venting the Heating System").  Fill the heating system to a pressure of 2 bar.  The pressure in the heating system should not fall below 1 bar.

11. Check that the central heating controls are calling for heat and the system begins to warm.

13. Slowly open a hot tap in the property. Check to see if the units LED shows a blue blinking light (C). Open the hot tap completely when the system is fully bled and leave it running for approximately 5 minutes. After 3 to 5 minutes check the water temperature at the tap is between 45&deg;C and 60&deg;C (Depending on the setpoint).

14. Bleed the unit. (see chapter "Venting the Heating System").

15. Close the hot tap in the property. The LED will now show a green blinking light (C)


{{IMGC|SPLIT Connecting Power.jpg|600}}

==Stage 8 - Re-fitting the front cover==

{{IMGC|SPLIT Fitting the cover.jpg|600}}

==Wilo Pump Settings==
{{:Wilo_Pump_Settings}}

==Troubleshooting for End users==

{{:Table:_DATA_End_User_Troubleshooting}}

==Troubleshooting (for Technicians)==

{{:Table:_DATA_Advanced_Troubleshooting|Troubleshooting for technicians}}

==Zenner Ultrasonic Heat and Cooling Meter==

{{:Zenner_C5_Heat_Meter}}

==Flamcovent Clean Smart Dirt and Air Separator==

{{:Flamcovent_Clean_Smart_Dirt_and_Air_Separator}}

==Guarantees and After Sales Backup for HIUs==

{{:Guarantees_and_After_Sales_Backup_for_HIUs}}


{{IMGC|SPLIT CE Declaration.pdf|600}}