Installation Instructions for the Data Split HIU

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Contents

Explanation of symbols and abbreviations

Symbols

Symbols.jpg

Abbreviations

Abbreviations.jpg

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

DATA SPLIT Parts ID.jpg


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

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.
SPLIT Options.jpg

Dimensions

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

SPLIT dimensions.jpg

Technical Data

Primary
Nominal primary supply temperature 80°C
Maximum primary supply temperature 95°C *
Minimum primary supply temperature 55°C **
Maximal primary differential pressure (without dP regulator) 250kPa
Maximal primary differential pressure (with dP regulator) 450kPa
Minimal primary differential pressure 50kPa ***
Pressure class DH circuit PN16
Domestic Hot Water
Nominal DHW supply temperature 55°C
DHW Set Range 45°C to 60°C
Domestic Hot water heat exchanger (DHW) E8LAS‐40
Keep Warm Modes Economy / Comfort
Keep Warm Temperature 25°C to 60°C
Keep Warm Duration 0 to 120 mins or Always On
Max Return Temperature during Keep Warm Mode DHW Setpoint -2°C
DHW Max pressure 6 Bar
Pressure class DHW circuit PN10
Central Heating
Maximum flow temperature Primary T -5°C
Return Temp Limit Range 35°C to 65°C
CH Limit Range 30°C to 80°C
Central heating heat exchanger (CH) E8LAS‐40
Pressure class CH circuit (3 bar safety valve) PN10
CH working pressure 2.5 Bar (Max 3 Bar)
Nominal pump pressure 20 kPa (Adj. 0-70)
Maximum recommend flow rate 750 l/hr
Pump Over-run 15 Mins (Adj. 0-1440)
Pump exercise function 60 Sec / 24 hr
General
Primary connections ¾” Female / 18mm
Mains & DHW connections ¾” Female / 18mm
Central heating connections ¾” Female / 18mm
Pressure relief 15mm
Casing width 490mm
Casing height 640mm
Casing depth 275mm
Casing Material EPP Expanded Polypropylene
Maximum Heat Losses <50W (1.2 kWh/day)
Typical Heat Losses (DHW Only, Keep Warm) 20W
Weight (basic version) 19.5kg ****
Electrical supply info 230V 50Hz - 0.64A
Power consumption per year circa 45kWh
Fuse ratings 3 Amp
Sensors NTC 10kohm @ 25°C

.* Maximum primary supply temperature 100°C for momentary spikes.
.** Minimum required DH supply temperature is DHW setpoint + 5°C with a minimum of 55°C.
.*** Depends on requested DHW output and available DH supply temperature.
.**** Unit weight may vary depending on the optional components built into the unit.

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°C and +40°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°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°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°C for at least 60 minutes every 24 hours. (it is not possible to specify the time at which this occurs)

Caution.jpg

The hot water temperature is regulated to temperatures as high as 60°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:

Setting Options Default
Domestic Hot Water Temperature 45°C to 60°C 50°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°C to 65°C Enabled 50°C
Maximum Central Heating Temperature 30°C to 80°C 80°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

NEW COMPLETE SYSTEM INSTALLATIONS: When carrying out a completely new heating system installation in a new build property or a first time installation in an existing property, then the heating system must conform to current building regulations Part L1a. All new domestic heating systems must have a minimum of two heating zones. Each of these zones should be controlled by a thermostat and zone valve. Alternatively individual electronically controlled Thermostatic Radiator Valves may be fitted. If domestic hot water is provided by a storage system then the storage system or cylinder will require separate time and temperature control.

All radiators must have TRV's fitted in all rooms except bathrooms and any rooms where a thermostat is located. The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.

EXISTING INSTALLATIONS: When carrying out boiler replacements on an existing system, the regulations do not require separate zoning of the upstairs and downstairs and compliance with the regulations can be achieved by a single room thermostat or programmable room thermostat. It is however recommended that TRV's are fitted to all rooms except the bathrooms and the room where a thermostat is located.

The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements.

BRITISH & IRISH STANDARDS Where no specific instruction is given, reference should be made to the relevant British and/or Irish Standard codes of Practice.

  • BS7074:1 Code of practice for domestic and hot water supply
  • EN12828 Central heating for domestic premises
  • BS7593 Treatment of water in domestic hot water central heating systems
  • ECTI National rules for electrical installations

POTABLE WATER: All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

FITTING AND MODIFICATIONS: Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer. Any misuse or unauthorised modifications to the appliance or associated components and systems could invalidate the guarantee and may lead to serious injury or even death. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

SERVICING: The end user should be advised to have the system serviced annually by a competent engineer. Contact Thermal Integration Ltd for a list of approved engineers. Approved spares must be used to help maintain the economy, safety and reliability of the appliance. The service engineer must complete the Service Record after each service.

General Wiring Requirements

These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. Component specific electrical information may also be supplied in support of these instructions, however if there is any doubt please contact Thermal Integration Ltd. (Tel: 0345 2411441)

FAILURE TO INSTALL APPLIANCES CORRECTLY COULD LEAD TO PROSECUTION.

The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements.

BRITISH & IRISH STANDARDS: Where no specific instruction is given, reference should be made to the relevant British and/or Irish Standard codes of Practice.

  • BS7074:1 Code of practice for domestic and hot water supply
  • EN12828 Central heating for domestic premises
  • BS7593 Treatment of water in domestic hot water central heating systems
  • ECTI National rules for electrical installations

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

Danger of short circuit: When connecting the cables ensure that no cable pieces fall inside the control panel.

The Mains supply to the appliance must be through a fused double pole isolator situated next to the appliance. The isolator must have a contact separation of 3mm minimum in all poles and should isolate the appliance and all associated controls.

Unless otherwise stated, all Heat Interface Units should be connected to a mains 230V 50Hz Supply fused at 3 Amps.

All electrical connections with the Heat Interface Unit control panel are clearly marked as follows:

  • L = Live 230V
  • N = Neutral
  • E = Earth Earth Symbol.jpg

Any additional mains cable should comply fully with the current I.E.E. wiring regulations. It must have a minimum section of 0.75mm2 and be capable of withstanding a minimum of 85°C.

Schematic

SPLIT Schematic Image.jpg

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.

Power supply.jpg

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.


Important Note.jpg

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.

Full Wiring Diagram with Ethernet Billing

Data wiring1.jpg

Important Installation Requirements

Caution.jpg

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°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.


Central Heating Isolation.jpg

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







.

.

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.

DHW Recirc Isolation.jpg

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

Caution.jpg

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°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.


Warning message.jpg


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°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

E8LASx40 DHW Performance Chart.jpg

.


.

DHW Power Chart for 10-55°C

Domestic Hot Water Power Output 10-55.jpg

Primary Return Temperatures for 10-55°C

District Heating Return Temperature 10-55.jpg

Primary Flow Rates for 10-55°C

District Heating Flow Rate 10-55.jpg

Primary Pressure Drop for 10-55°C

Pressure Loss (Primary) 10-55.jpg

Domestic Hot Water Pressure Drop for 10-55°C

Domestic Hot Water Pressure loss 10-55.jpg

Central Heating

Central Heating Temperature Curves for 80-50°C

STD DATA SPLIT Heating Temperature Curves - E8LAS x 40 (rev 1).jpg

Central Heating Temperature Curves for 70-40°C

STD Heating Temperature Curves - E8LAS x 40 - 70-40 systems (rev. 05).jpg

Central Heating Temperature Curves for 60-40°C

STD Heating Temperature Curves - E8LAS x 40 - 60-40 systems (rev. 05).jpg

Central Heating Temperature Curves for UFH 45-35°C

STD Heating Temperature Curves - E8LAS x 40 - UFH systems (rev. 05).jpg

Installation Set-up

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


Installation setup.jpg


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.

Case Removal.jpg

Stage 2 - Pipe Connections

Pipe Connections2.jpg

Stage 3 - Mounting the HIU

Plumbjig Connection.jpg
Plumbjig Connection2.jpg

Stage 4 - Installing the Heat Meter

SPLIT Fitting Heat Meter.jpg
SPLIT Fitting Heat Meter2.jpg

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.

Warning message.jpg

Connecting the programmer / room thermostat:

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


Important Note.jpg

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.

SPLIT RT Cable.jpg

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.


Important Note.jpg

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.

SPLIT AAV.jpg

Stage 7 - Commissioning

Follow the steps below for connecting and commissioning the HIU.

Warning message.jpg

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) Earth Symbol.jpg

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°C and 60°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)


SPLIT Connecting Power.jpg

Stage 8 - Re-fitting the front cover

SPLIT Fitting the cover.jpg

Wilo Pump Settings

The heat interface unit is fitted with one of two central heating pumps. The pumps can be adjusted to fit the end users situation. By default, the pumps are placed in the maximum setting with a constant differential pressure.

Adjustments to the pump settings should be done by recognised personnel only. Please use caution when adjusting the unit. Parts can be hot or energized. Contact with these parts may lead to shock, burn or electrocution.

 

The Wilo pump is fitted with Red Knob technology. The knob opens the possibility to toggle between different settings:

  1. Selecting the setup type
  2. Setting up the desired differential pressure (H)
  3. Activating the pumps bleeding function
Data wpump.jpg

 

Bleeding

  Setting up Pump Head  

The pump will bleed itself at first startup. If the pump does not bleed itself, follow the steps below:

Data gpump3.jpg
  1. Switch to bleeder mode
  2. Bleeder function will start after approximately 5 seconds and will take about 10 minutes to complete
  3. When bleeding is finished, switch the red knob back to the preferred setting

 

        

Pump settings are marked in metres pressure head, up to a maximum of 8m.

The differential pressure setting increases the head the pump generates as the flow accepted by the system increases. This setting can assist in reducing noise at low loads, as well as allow for long pipe runs where pressure losses become more significant at higher loads.

 The constant pressure setting maintains a set head at all flow rates, modulating the pump up and down as load increases to maintain the same head.  

 

Data gpump2.jpg

Data gpump1.jpg
The recommended setting is No. 2 (approximately 20 kPa) in constant pressure mode. Wilo Constant Pressure.jpg

Wilo Pump Setting.jpg

Troubleshooting for End users

What can you do?

Warning message.jpg

Always take in account the safety of yourself and others when performing a troubleshoot.

Leakage
1. Close all valves on the plumbing bracket under the unit and the mains cold water feed.
2. Contact your engineer.
Central Heating Circuit does not warm up
1. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.
2. Make sure the valves on the plumbing bracket are open (handle in vertical position).
3. Check radiator valves are open and calling for heat.
4. Check the programmer is set to ON, and calling for heat.
5. Set the room thermostat higher.
6. Problem solved? If not, contact your engineer.
No domestic hot water
1. Check that the mains cold water valve is open. If not, open the main valve.
2. Problem solved? If not, contact your engineer.
Tap water does not warm up
1. Ensure that all valves on the plumbing bracket under the unit and the main valve are open.
2. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.
3. Problem solved? If not, contact your engineer.
Sound
NOTE: It is normal that the HIU makes noise when hot water or heating are active. Also, the electronic valves will make a light (buzzing) noise during movement. If the HIU starts to make any loud or disturbing noises, contact your installer.

Troubleshooting (for Technicians)

Troubleshooting for Technicians.jpg

Zenner Ultrasonic Heat and Cooling Meter

The Zenner Zelsius® C5 ultrasonic heat and refrigeration meter operates with an innovative ultrasonic technology, specially developed for domestic energy measurement. Thanks to a combination of modern measuring technology and a very compact design, this meter is perfectly suitable for recording all accounting data for measuring energy consumption in heating and/or refrigeration plants. The wear-free ultrasonic technology is impervious to debris, stable over the long term and is also reliable for very low volume flow rates.

Zenner C5 Heat Meter.jpg

Features and Performance Criteria

  • Available as heat, cooling or combined heat/cooling meters
  • Low design height
  • Wired or wireless M-Bus (optional)
  • 2 or 3 pulse inputs or outputs (optional)
  • Any installation position (even overhead)
  • Stores 24 months readings
  • Powered entirely by the M-Bus network or M-Bus Master
  • Up to 11-year battery backup, if disconnect from the M-Bus network
  • Precise, long-term stable, wear-free
  • Very wide dynamic range
  • Conforms to MID, Class 2

Part Codes

ZE101C5 15MM C5 IUF Ultrasonic Heat/Cooling Meter. 0.6m3/h, 110mm body length

ZE102C5 15MM C5 IUF Ultrasonic Heat/Cooling Meter. 1.5m3/h, 110mm body length

ZE103C5 20MM C5 IUF Ultrasonic Heat/Cooling Meter. 2.5m3/h, 130mm body length

ZEC5MBO C5 M-Bus Output

ZEC5WMB C5 Wireless M-Bus Output

ZEC5PUO C5 Pulse/Radio Output

ZE200PO Pocket or Ball Valve 5.2mm, 50mm, 34.5mm

ZE015CO 15mm Couplings G3/4 R1/2 (pair)

ZE020CO 20mm Couplings G1B R3/4 (pair)

Further Documentation

C5 IUF Conformity Cert MID

C5 IUF Ultrasonic Heat Meter Data Sheet

C5 Installation Guide

Wiring Guide

All CablesSensor CablesMBus CablesPulse Cables

Flamcovent Clean Smart Dirt and Air Separator

Flamcovent Clean Smart
Flamcovent Clean Smart Insulated

Air bubbles and dirt particles are always present in the water of cooling and heating systems. The dirt can accumulate and cause blockages. The use of filters is not ideal because these do not trap smaller particles, silt up and then have to be regularly cleaned or replaced. Air and gases in a system are generally a consequence of activities performed, micro-leaks and of electrolysis and chemical processes in the water.Traditional de-aeration devices extract insufficient gases from the water, leaving microbubbles behind.

Air and dirt in a system cause problems such as unnecessary faults and extra wear or noise, but also lead to disruption of the system, lower heat transfer and reduced pump performance. The new Flamcovent Smart, Flamco Clean Smart and Flamcovent Clean Smart air and dirt separators are now offered as standard alongside all systems to provide reliable protection of the primary system.


  • 60% better performance compared to conventional air and dirt separators.
  • Suitable for temperatures of up to 120°C.
  • Suitable for operating pressures of up to maximum 10 bar.
  • Unique flow velocities, up to 3 m/s.
  • Can be used with all kinds of pipework.
  • Compact dimensions, light weight.
  • Available in various sizes up to 2".
  • Extremely low flow resistance and low loss of energy.
  • Consistent performance throughout its service life.


FlamcoventCleanSmart_ENG_DEF_2014

Guarantees and After Sales Backup for HIUs

Heat Interface Units (HIUs) carry the following guarantees as standard:

FACTORY WARRANTY

1. The warranty begins on the date of delivery. A dated delivery note will be issued to the customer and a copy will be stored by Thermal integration.

2. 12 Months Parts and labour - Parts or labour proven to be defective will be replaced / repaired free of charge for a period of 12 months from date of delivery, provided the HIU is installed by a qualified engineer within 6 months of date of delivery.

24 Months Parts Only - Parts proven to be defective will be supplied free of charge (for fitting by others) for a period of 24 months from date of delivery.

3. Replacement of parts under warranty does not extend the duration of the warranty.

4. Any other costs are not covered by this warranty. All other damages of any nature whatsoever and howsoever arising, are expressly excluded from this guarantee.

5. The warranty conditions above only apply:

a. In the UK only on items provided exclusively by Thermal Integration.
b. If the product is installed by a Thermal Integration approved engineer in compliance with the installation instructions.
c. The installer must complete the commissioning checklist in full at the time the HIU is installed. This checklist must be returned to Thermal Integration within 30 days of commissioning. Checklists are enclosed in the HIU installation instructions.
d. If the installation complies with all current and relevant building regulations and codes of practice. (including the requirement to clean the primary and secondary heating systems and add corrosion inhibitor in line with BS7593:2006)
e. If the product is used and maintained exclusively according to the manufacturer's instructions and proof of periodic inspection / maintenance by a Thermal Integration approved engineer is available.
f. If the returned item is accompanied by a fully completed Thermal Integration Warranty Return Form.

6. Excluded are defects caused by:

a. Failure to maintain in accordance with manufacturer’s instructions.
b. Improper use.
c. Any attempt at repairs / maintenance by un-qualified persons.
d. where parts other than Thermal Integration Genuine Parts have been used in any service or repair.
e. Lightning, fire or natural disasters.
f. Deterioration and / or pollution from the district heating system or water network, either domestic hot water or heating side.
g. PH values of the primary medium being less than 7.5 or greater than 9.0.
h. Harmful additives to the heating water.
i. Consumables as specified by us, including but not limited to: hoses, gaskets and batteries.

7. Report any faults to your installer, service engineer or Thermal Integration directly. Faulty parts must be accompanied by a fully completed Thermal Integration Warranty Return form, to be returned to Thermal Integration. Returned items remain the property of Thermal Integration Ltd.

The Thermal Integration Warranty Return Form can be requested by phone or email. Returns are not accepted unless expressly agreed in writing.
Transport risk of returned items lies with the sender. The shipping of replacement parts are the responsibility of the supplier.

8. If the HIU breaks down, we may ask you to pay us a deposit before we visit you to repair it. We will return the deposit in full if we find a fault that is covered by this warranty. We may keep the deposit if we cannot access your property at the time we had arranged with you to visit or we find other conditions of this warranty have not been met. A responsible adult must be at the property to give our engineer this access to the HIU.

9. COMMISSIONING
Thermal Integration offer commissioning services across the UK. The service includes:

a. The fulfilment of the defined commissioning instructions.
b. Completion and return of site wide commissioning paperwork.
c. Rectification of any HIU problems.
d. Confirmation of HIU performance to contract specifications.
e. Engineer travel and subsistence.

Commissioning rates are charged on a whole day basis, and it is the responsibility of the client to ensure:

a. Safe access to properties and HIUs
b. Correct operation of central plant with delivery of heat to HIUs at specified temperatures, flow and pressures.
c. All pipework has been correctly tested and flushed.
d. Credit on billing system to enable security valve.

A minimum 2 weeks notice is required in writing to Thermal Integration before the requested commissioning date.

SERVICE
Technical assistance and engineer backup can be obtained by calling our offices:

FURTHER INFORMATION

The Heatweb Wiki website at www.heatweb.com/wiki contains information on all aspects of HIU design, function, and servicing, and is always the best place to visit for additional documentation or how to guides.


File:SPLIT CE Declaration.pdf