rehau intelligent Ba heating/cooling controls technical & installation manual Building Solutions Automotive Industry

Transcription

1 rehau intelligent Ba heating/cooling controls technical & installation manual Building Solutions Automotive Industry

2 REHAU Intelligent Floor heating/cooling COROS Index Principles of Underfloor Heating/Cooling Principle of UFH Principle of UFC Fixed Flow Water emperature (FF) System Zone Control Set Back Mode Fixed Flow emperature Control Required Components for Fixed Flow emperature Control Fixed emperature Mixing Options Compact Mixer Unit Working Principle Installation a..... Before the System is Switched On hermostatic Mixing Valve (MV) Working Principle Installation Required Components for Zone Control Wiring emperature Safety Options High imit Sensor (HS) Working Principle Dew Point Control Installation Port Zone Valve (ZV) Working Principle Installation REHAU Intelligent Heating/Cooling Control Systems Components Overview Components Overview Heating Components Overview Heating/Cooling Components Overview Wireless Sensors/Controllers Working Principle Required Components for Zone Control

3 REHAU Intelligent Floor heating/cooling COROS Index Control System First Fix Components Overview Positioning the BA Master Controller Room Sensors and Remote Air/Floor Sensors ocation of Room, Humidity Sensor and Air Sensor Positioning the Remote Air Sensor Positioning the Floor Sensor Control System Second Fix REHAU BA Central Control Units Electrical Connection Boiler Connection Pump Outputs - UFH Pump Connecting REHAU Add On, Extension Modules Connecting Room Sensors Connecting hermal Actuators (H H 8) External Switch/imer Room Sensors Internal Connections Connect the Wiring a..... Connect the Remote Air Sensor Floor Sensor Option (D Sensor Only) Connecting the Floor Sensor Wireless Sensors/Controllers Set Up Radio Frequency (RF) Set Up echnical Data Setting Up BA Master Controller (Cooling) Offset to Day emperature ight Setback emperature (SB) BMS Used for Heating/Cooling Change Over Decision Exceeded Dew Point Using Dehumidifier Dew Point Control Volt Free Output Signal for Chiller/Reversible Heatpump System Start Up and Operating Instructions Setting the Sensor Channel umber REHAU BA Master Controller

4 Commissioning Pre-commissioning Requirements he Commissioning eam C Set Up Guide Programmable Room Sensor, Domestic Hot Water, Radiator and wo Stage Controller Domestic Hot Water (DHW), Radiators and wo Stage Controller Domestic Hot Water Radiators wo Stage Room emperature Controller Special Functions etwork Multiple Controllers Dip Switches Holiday Override Function Checking Control System Operation roubleshooting and Error/Fault Messages roubleshooting Error/Fault Messages Voltage Measurements Resets Replacing Faulty Sensor/Controller Sensor Failure/Actuator and Pump Exercise Sensors/Controller Failure Actuator and Pump Exercise Wiring Schematic - ext Generation

5 REHAU Intelligent Floor heating/cooling COROS Index If a floor heating system is added to an existing heating or hot water system, containing mild steel pipes, a strainer must be fitted straight after the branch off. All REHAU control systems must be installed. - By a competent person - In accordance with the latest issue of instructions supplied with each component - According to the current IEE wiring regulations laid out in BS 767 and ational Valid regulations and in compliance with the ordinances stipulated by local power authorities. Diagram/DWG egend AC Actuator AV Air Vent BPV Bypass Valve BV Balancing Valve CP Circulating Pump CS Cylinder Sensor C Programmable Room Sensor OS Outside Sensor CY Cylinder DHWS Domestic Hot Water System EV Expansion Vessel FM Flow Meter HS High emperature imit Stat IV Isolating Valve SV Radiator ock Shield Valve REHAU Intelligent Controls V MOV RS BC SP A D IV M MV P RV ZV Variable emperature Motor Operated Mixing Valve Room Sensor Boiler Controls System Pump Standard Sensor Room Sensor with identical features of M, along with floor sensor hermostatic Inlet Valve Room Sensor with four modes Auto, Day, ight and Frost protection hermostatic Mixing Valve amper Resistant Sensor hermostatic Radiator Valve -port Zone Valve echnical Data Power Supply Max load pumps and hermal actuators Boiler relay Main pump (Volt free relay) Secondary pump hermal actuators Max. 0VA per output. Max. VA in total Optional External Switch (imer) for night setback Room sensor Bus wire low voltage Application sensor and imit sensor Control signal for mixing valve actuator Power supply for mixing valve actuator 0V AC 0/-%, 0 HZ A VA Volt free signal. Max A Volt free signal. Max A 0V AC, 0Hz Max. A Max. 0VA on each output Max. VA in total Open terminals for night set back and closed terminals for day operation v C type EF-899A for water temperature 0-0V DC V AC. Max 6VA

6 .0. Principles of Underfloor Heating/Cooling Principle of UFH hermal Comfort REHAU underfloor heating system operates on the basis of low surface temperatures and even temperature distribution across the whole floor with comfortable radiant energy. In contrast to other heating systems the radiative equilibrium between occupants and the surfaces in a room is established and an optimum level of comfort is achieved. Energy-saving Due to the REHAU underfloor heating systems high proportion of radiant energy, comfort conditions can be achieved with lower room temperatures typically ºC to ºC. his facilitates a typical annual energy savings of 6% to %. Environmentally friendly Due to the high heat output, even at low flow temperatures, the REHAU sub-surface heating systems are ideal for use in combination with gas condensing boilers, ground source heat pumps or thermal solar power systems. Good for allergy sufferers hrough the REHAU underfloor heating systems low proportion of convective energy only a minimal thermal vortex is formed. Dust circulation and the carbonising of dust are thus a thing of the past. his protects the airways - not just those of allergy sufferers. Visually attractive rooms without radiators he REHAU underfloor heating / cooling systems - Allow the user to be free with their interior design - Gives the architect the planning freedom - otally eliminates risk of injury and burning from surface mounted heat emitters. Hence totally suitable for nurseries, schools, hospitals, clinics etc. - ower maintenance costs. Operative emperature according to CIBSE* Winter Summer In living spaces and lounges -ºC -ºC In bathrooms 0-ºC -ºC * CIBSE Guide A, Environmental Design Red - warm uncomfortable Orange - comfortable Yellow - still comfortable Blue - cold uncomfortable. hermal comfort, dependent on the room air temperature R and the temperature of the surfaces Room air temperatures according to BS E 8 - In living spaces and lounges: 0ºC - In bathrooms: ºC. enclosing the room F Exemplary temperature profiles in heated rooms Surface temperatures Maximum permissible floor surface temperatures are to be observed for the surface as a surface in direct contact with people for medical and physiological reasons: - Occupied zone 9ºC - Peripheral zone ºC (generally situated along in the floor near large glazed areas).. Radiator heating. Sub-surface heating. Ideal heat distribution

7 .0. Principles of Underfloor Heating/Cooling Principle of UFC Advantages of a Underfloor Cooling System - High level of comfort - Draughts do not occur - ow investment costs - ow annual costs - Preserves resources - Unrestricted interior design. hermal comfort he thermal comfort for one person in a room is determined by: - he person s activity - he person s clothes - Air temperature - Air speed - Air humidity - Surface temperatures. he heat output of the human body occurs via main three mechanisms: - Radiation - Evaporation - Convection. he human body experiences the greatest level of well being if it can regulate at least 0% of its heat output through radiation. With the REHAU underfloor cooling system the energy exchange between people and cooling surface occurs across large areas and predominantly through radiation and thus provides the optimum conditions for a comfortable room atmosphere. Classic air conditioning systems raditional air conditioning systems overcome the cooling loads that occur by changing the air, with the following negative effects: - Draughts - High room air speeds - Cold supply air temperatures - High sound level. his can often result in uncomfortable air conditions for the user, also referred to as sick building syndrome. Economic disadvantages of traditional air conditioning units: - High investment costs - High annual running costs. Cooling capacity he standard cooling capacity of the REHAU underfloor cooling system is 0W/m in accordance with DI 7-. he performance estimation was carried out with: - RAUFIX system - Distance between pipes 0cm - RAUHERM S 6 x.mm - Coolant temperature 0K - emperature spread K. Under practical conditions, with - surface temperature of 9-0ºC - room temperature of 6ºC values of -0 W/m can be obtained. 0ºC ºC. he human being s heat balance 0ºC 0.m/s. Air temperatures and air speeds with pipe underfloor cooling Radiation Min 0% Evaporation <0% Convection <0% Heat distribution <-% Influencing factors on the cooling capacity he sub-surface cooling system s maximum achievable output is dependent upon: - floor covering - pipe spacing - pipe dimensions - floor construction - heat gains - system However, each of the factors affects the cooling capacity to a different degree. he floor covering and pipe spacing have a substantial impact on the output of the cooling system. It is recommended that only stone, tile or slate type floor or other low resistivity floor coverings are used to maximise the cooling output 6

8 .0. Principles of COROIG FOOR HEAIG SYSEMS (FH) Fixed Flow water temperature (FF) System A conventional boiler system including radiators and domestic hot water (DHWS) provides water with a flow temperature in the region of 80ºC. Water is pumped by a Main (system) pump to the hot water cylinder and to the radiators, where it loses temperature and on the return, the water temperature normally stays at around 69ºC. Current standards and regulations for floor heating state that the surface temperature of a floor must not exceed 9ºC (in perimeter zones and bathrooms ºC). In a traditional underfloor circuit the flow and return water is mixed via a mixing valve to achieve a flow temp of between ºC-ºC. his is achieved by mixing the boiler flow with cooler water from the return of the floor heating circuits. Once flow set point is achieved the mixing valve closes to the boiler to stop excess temperature rise. Commonly there are two main systems in use: - Fixed Flow emperature (FF) system - Variable Flow emperature (VF) system (also known as weather compensated system). A constant temperature system regulates the amount of warm water being added from the main system boiler to the water circulating within the circuits, to maintain the flow temperature in the circuits at a pre-set level. his constant temperature is mechanically pre-set at a thermostatic mixing valve (MV). It is not possible to influence the mixed water temperature remotely by a building management system (BMS). For domestic and smaller commercial applications requiring a constant temperature system, REHAU offers a small and compact mixing unit called the compact mixer unit. It is supplied pre-assembled and is ideal for installations where space is limited. For larger commercial applications, a traditional system using a -Port thermostatic mixing valve is recommended. 7

9 .0. Principles of COROIG FOOR HEAIG SYSEMS (FH) ZOE CORO Master Controller ZV MV IV CP IV IV HS AC AC AC AC UFH - Flow UFH - Manifold UFH - Return R R R R. Individual zone control with FH he REHAU IEIGE zone control system is a simple electronic control system that has been specifically designed to give optimum and accurate control of Floor Heating systems. Heating/Cooling circuits are connected to a central manifold. Each circuit will have a thermoelectric actuator (AC) on the manifold operating the return valve for the circuit. In heating mode: he heat output in each room is controlled by a room sensor (RS), which continuously compares the required room temperature with the actual room temperature. If the room temperature is too low/high, it will signal the actuator (AC) to open the return valve of the circuit and allow warm/ cold water to flow through it. (As shown in Fig. ). In cooling mode: he cooling output in each room is controlled by a room sensor (RS), which continuously compares the required room temperature with the actual room temperature. If the room temperature is too high, it will signal the actuator (AC) to open the return valve of the circuit and allow cool water to flow through it.. Set Back Mode A floor heating system switches into set-back mode instead of switching off completely. his means when you leave the house or at night, the system allows the internal temperature to drop to a lower level. Depending on the installed system components, this reduced temperature level can be set for each room individually or for a group of rooms. Zone controls give control over local/room temperature by adjusting the amount of water circulating within individual circuits/ zones. Adjustments are made dependent upon: - Continuous temperature readings from each room sensor (RS) - he end user settings such as room temperature set point and programmed night set-back periods on the timer 8 he pre-set temperature for this mode should be carefully selected, because if the temperature is set too low the system will require a large initial input of energy coupled with a long response time to raise the temperature again. he set back mode enables the system to respond quickly and efficiently when heat is required. It can also make it possible to use a smaller boiler compared to a conventional heating system.

10 .0. Fixed FOW temperature control required components for fixed FOW temperature control Authorised Specialists Installation, commissioning, maintenance and repairs of all electrical control components shall only be carried out by trained, competent and qualified specialists in accordance with the national, valid regulations (Health & Safety, Wiring Regulations, etc) and in compliance with the ordinances stipulated by the local power authorities. his table should help you in identifying which components you need dependent on your choice of flow temperature control. More details on each control option and how they are installed and electrically wired are given in the subsequent sections. Sources of Danger Before opening any component always ensure the system is switched OFF at the main heating system isolation switch. o clean the components use a dry towel only. ever clean the unit with water or other solvents (e.g. spirit, acetone). ever touch any live component with wet hands. Designated Application All equipment explained in the following sections is intended for mixing flow and return water to a suitable mixed water temperature for use with wet floor heating. Modifications or changes to this equipment are only permitted with the manufacturer s approval. he manufacturer does not accept liability for damages arising from misusing the equipment. Constant emperature hermostatic Mixing Component REHAU Art. o. Compact Mixer Unit Valve Configuration Compact Mixer Unit 709 x o ½" Balancing Valve (BV) ½" IV (for outputs up to kw) 70 x¹ o ¾" Balancing Valve (BV) ¾" IV (for outputs up to 8kW) 0 x¹ o Bypass Valve ot supplied x x Male iron to copper adapters ot supplied o o Circulating Pump with x isolating valves ot supplied o x Manifold Isolating Valves Incl. with Manifold ot used x High emperature imit Stat Included x -Port Zone Valve (mm) for outputs up to kw 06 x² x² -Port Zone Valve (8mm) for outputs kw to 8kW 07 x² x² ) Only one balancing valves required, size depending on output ) Only one zone valve required, size depending on output 9

11 .0. fixed FOW temperature control Fixed temperature mixing options.. Compact Mixer Unit - Only for domestic/light commercial applications - For outputs up to kw use /" valve set (not to be used to size primary pipes) - For outputs between - 8kW use /" valve set (not to be used to size primary pipes) - he circulating pump only circulates the warm water through the circuits. A separate main system pump is needed to supply the manifolds with hot water from the boiler... Working Principle he compact mixer regulates the main system flow from the boiler directly into the manifold. It mixes the high temperature water from the main system flow (usually required temperature 70 C), with the cooler water from the FH return of the circuits to ensure the right temperature. he thermostatic inlet valve (IV) allows small amounts from the main system flow to enter the return header, where it mixes with the return water from the circuits. he circulating pump (CP) maintains an uninterrupted flow of water from the return header up into the flow header and back into the floor circuits as long as there is a demand signal present from any of the room sensors. he temperature of this mixed flow is measured by the in-line temperature probe, which feeds back to the thermostatic head on the (IV). he thermostatic head of the thermostatic inlet valve (IV) is set to achieve the required design flow temperature. Once the required design flow temperature is detected by the in-line temperature probe it closes the thermostatic inlet valve (IV), o further main system flow is allowed into the return header, until the measured temperature falls below the design flow temperature. he unit also features a high temperature limit stat (HS) which is explained later in the section on emperature Safety Options. 6. Compact Mixer Unit System Return Balancing Valve BV System Flow 0 ± ca 9 6 ca 6 ca. 0 or æ UFH Manifold (not included in compact mixer) or æ hermostatic Inlet Valve IV Manifold Ports Approximate ength in mm Compact Mixer Connector Block UFH Pump Additional space of 60mm required to access inline temperature probe for thermostatic inlet valve Inline emperature Prove of IV ee Connector with Drain Valve (see table below) UFH Flow Header UFH Return Header High emperature imit Stat HS Air Vent Manifold Ports Approximate ength in mm Inline HS emperature Probe emperature Guage emperature Guage Inline HS emperature Probe (see table below) Air Vent UFH Flow Header UFH Return Header 6 High emperature imit Stat HS UFH Manifold (not included in compact mixer) Compact Mixer Connector Block UFH Pump Additional space of 60mm required to access inline temperature probe for thermostatic inlet valve Inline emperature Probe of IV ee Connector with Drain Valve 7. Compact Mixer Unit fitted to the right side of the manifold with FH flow header on top, FH return header on bottom 8. Compact Mixer Unit fitted to the left side of the manifold with FH flow header on top, FH return header on bottom hermostatic Inlet Valve IV 6 ca.9 Balancing Valve BV or æ ca.6 ca.0 System Return 0 ± System Flow 0

12 Junction Box C/HW BA Controller CMU HWS C/R C/HW SV ZV HS AV BPV SV PV CS RS MV SV RV Compact Mixer Unit Hot Water Supply Radiator Controller Domestic Hot Water Controller Safety Valve Zone Valve High temperature imit hermostat Air Vent By pass Valve Safety Valve Pressure Vessel Cylinder Sensor Room Sensor hermostatic Mixing Valve ock Shield Valve hermostatic Radiator Valve PV HWS Hot Water Cylinder SV Boiler Hot Water Sensor CP AV ZV RV BPV C/R Radiator SV ZV RS Manifold Flow Header Manifold Return Header HS CMU 9. Hydraulic layout of REHAU Compact Mixer Unit with S plan Integration.. Installation Supplied Required Components Qty by REHAU REHAU Compact Mixer Unit x Yes REHAU Valve Set x Yes Fitting - he compact mixer comes pre-assembled, ready to fit onto the right hand side of the REHAU manifold. It can be integrated into an existing radiator system via an 'S' plan type control system. (As shown in Fig. 9) Due to the inability of a -Port mid position valve to isolate both system ports i.e. DHW & Radiators, it is recommended that this type of valve is not used with the Floor Heating system. - If a module needs to be mounted onto the left side of the manifold: - the pump inlet / outlet connections must be loosened first - rotate the pump 80ºC - connections tightened again - temperature gauge and opposite blanking plug unscrewed - gauge and plug swapped over and screwed into tee adapter. - he compact mixer is screwed onto the manifold flow/return headers. Care should be taken that all connections are securely tightened - Balancing valve (BV) and thermostatic inlet valve (IV) are screwed onto the opposite ends of the manifold headers. (Balancing valve (BV) to the FH flow header and thermostatic inlet valve (IV) to the FH return header) - he probe of the thermostatic inlet valve (IV) should be carefully inserted into the sleeve in the tee-connector underneath the circulating pump (CP) (return header). he thermostatic inlet valve (IV) must be fitted onto the system flow pipework from the boiler, not onto the return pipework to the boiler.

13 .0. fixed FOW temperature control Fixed temperature mixing options..a Before the system is switched on, the following settings have to be carried out: - Balancing valve (BV) set to fully open as per recommendations on the instruction leaflet supplied with the compact mixer - hermostatic inlet valve (IV) set to design flow temperature - High limit stat (HS) set ºC above design flow temperature (function explained in the section.. emperature Safety Options) - he compact mixer must be in position on the manifold before the electrical connections can be made - he pump live (brown) connects to the terminal of the secondary pump connection inside the control centre - he neutral wire (blue) connects to the terminal of the secondary pump connection inside the control centre - he earth wire (green & yellow) connects to the E terminal next to the boiler connection inside the control centre. (See Fig., see page 6). If the system is wired correctly, the pump should only run if there is a demand signal, i.e. a room sensor (RS) activates an actuator (AC). Circulating Pump Make Grundfoss (May Vary) Overall dimensions 0mm x 9mm x 0mm (H x W x )* Voltage 0v High emperature imit Sensor Make Oreg 90 Overall dimensions 90mm x 0mm x 60mm (H x W x )* emperature range 0 C to 90 C Wiring.6m, core flex (0.7mm²) Balancing Valve ype Up-and-over ½" or ¾" Female-male Overall dimensions 60mm x 0mm (H x )* Material Brass MS 6 (Body) hermostatic Inlet Valve Material Brass MS 6 (Body) emperature range 0 C to 0 C (different range on request) System pressure 0 bar Differential pressure bar (for system differential pressures greater than this, install pressure reducing valves prior to the thermostatic valve) emperature Gauge emperature Range 0 C to 80 C.. hermostatic Mixing Valve (MV) - Suitable for all applications, below 0Kw. Above this weather compensation is recommended - Use the correct size of mixing valve (according to required heat output: kw / 0kW or 0kW) - he circulating pump only circulates the warm water through the circuits. A separate main system pump is needed to supply the mixing valve with hot water from the boiler... Working Principle he boiler temperature main system flow enters the thermostatic mixing valve at 70ºC and is mixed with the cooler return water from the circuits as required. A circulating pump (CP) circulates water at the required design flow temperature through the circuits via the manifold flow header every time there is a demand signal from one of the room sensors. On the return from the circuits water is taken as required, and mixed with the main system flow. he remaining water is then routed back to the boiler. A wax capsule inside the thermostatic mixing valve (MV) expands and contracts with a temperature increase or decrease of the mixed water inside the valve. he pre-set design flow temperature on the valve is mechanically transformed into a pre-stop for the valve position. his means, that no more water from the main system flow can enter the circuits, once the correct flow temperature is reached. A so called closed circuit or loop is created between the thermostatic mixing valve (MV), the circulating pump (CP) and the manifold with its floor heating circuits. If the flow temperature falls below the design flow temperature, the thermostatic mixing valve (MV) allows additional water from the main system to flow into the circuit. he amount of water added is dependent on the temperature decrease, in certain cases the thermostatic mixing valve (MV) can fully open the main system flow port and fully close the return flow port. his will result in a quick response from the FH system to sudden increases in heat demand. * Dimensions are approximates only

14 o improve the response time even further it is recommended to fit a differential bypass valve (BPV) as close to the thermostatic mixing valve (MV) as possible. his can reduce the time it takes for the hot water from the boiler to reach the mixing valve...6 Installation Required Components Qty Supplied by REHAU Correct sized -Port hermostatic x Yes Mixing Valve (MV) Circulating Pump (CP) Isolating Valve of correct size (IV) x x o x (with manifolds) Bypass Valve (BPV) x o Fitting (always read and follow instructions supplied with components) - Identify on the valve the correct inlets for flow and return water as well as the outlet for the mixed water - Connect the boiler flow from the -Port zone valve into the inlet for hot water (identified with an H usually on the valve body) using the compression ring connections - Connect the collective return from the floor heating to the inlet for cold water usually (identified with a C on the valve body) using the compression ring connections - Connect the outlet for the mixed water usually (identified with MIX or arrow on the valve body) to the flow inlet side of the circulating pump (CP) via the isolating valve (IV) - Fit the circulating pump (CP) using isolation valves on both ports of the pump making sure the pump inlet is connected to the mixed outlet of the MV and the pump outlet to the flow header of the floor heating manifold. Wiring - he pump live (brown) should be wired into terminal () of the Honeywell high temperature limit sensor (HS) via terminal () of connector block. Article o. - he pump neutral (blue) wire is to be connected to terminal terminal of the secondary pump connection inside the control centre - he earth wire (green & yellow) connects to the E terminal next to the main pump connection inside the control centre. Junction Box C/ HW BA Master Controller HWS Hot Water Supply C/R Radiator Controller C/HW Domestic Hot Water Controller SV Safety Valve ZV Zone Valve HS High temperature imit hermostat AV Air Vent S emperature semsor (Flow) CP Circulating Pump BPV By pass Valve SV Safety Valve PV Pressure Vessel CS Cylinder Sensor RS Room Sensor MV hermostatic Mixing Valve SV ock Shield Valve RV hermostatic Radiator Valve PV HWS Hot Water Cylinder SV Boiler Hot Water Sensor CP AV ZV RV C/ R Radiator ZV BPV SV MV CP HS S RS Manifold Flow Header Manifold Return Header 0. Constant Flow Water emperature system with S plan Integration

15 .0. FIXED flow temperature control fixed temperature mixing options Data hermostatic Mixing Valves (Fixed Flow -Port) For up to kw: Dimensions : 0mm x 9mm x mm (H x W x D) Outlet temperature setting : ºC to 6ºC Hot water supply : max 90ºC emperature stability 9 nominal : ± ºC bar : approximately 6 l/min Body : Cast gunmetal, nickel plated Internal brass components : DZR brass Fittings : mm compression DZR brass For up to 0kW: Dimensions : 0mm x 9mm x mm (H x W x D) Outlet temperature setting : 0ºC to 60ºC Hot water supply : max 8ºC emperature stability 9 nominal : ± ºC bar : approximately 6 l/min Body : Cast gunmetal, nickel plated Internal brass components : DZR brass Fittings : mm compression DZR brass For up to 0kW: Dimensions : 6mm x 9mm x 7mm (H x W x D) Outlet temperature setting : ambient to 60ºC Hot water supply : max 8ºC emperature stability 9 nominal : ± ºC bar : approximately 00 l/min Body : Cast gunmetal, nickel plated Internal brass components : DZR brass Fittings : 8mm compression DZR brass Differential Bypass Valve (straight) Dimensions : 90mm x 76mm x mm (H x W x D) Opening pressure settings : 0. bar to 0. bar Max operating pressure : 0 bar Max operating temperature : max 0ºC Body : DZR brass Connections : mm compression

16 ..7 Required Components for Zone Control Masters/ Add On modules Quantity Components REHAU Art. o. Heating Heating/Cooling REHAU BA o Yes BA Cooling Kit 0-00 o Yes Add On, Module -00 Up to 8 zones: 0x Up to zones: x Wired Sensors/Controllers Components REHAU Art. o. Constant Flow emperature REHAU C (Programmable Room Sensor) Minimum:x (same time setting in all zones) Maximum:x (different time setting in all zones) REHAU P (amper resistant sensor) Up to 8 zones: maximum of 7x REHAU A (Standard Sensor) Up to zones: maximum of x REHAU D (Comfort plus sensor, includes floor sensor) 6-00 REHAU M (Comfort sensor) REHAU HS (Humidity sensor) 9-00 o Actuators 9-00 Minimum:x per controlled circuit Maximum:x per manifold / controller Switch fused spur ot supplied x et Extension kit If the distance between the master and the Add On Module exceeds 0.m, then net extension kit is required. his includes connector blocks each with small cables with RJ connectors Wireless Sensors/Controllers Components REHAU Art. o. Constant Flow emperature REHAU RF C-RH Minimum:x (same time setting in all zones) Maximum:x (different time setting in all zones) REHAU RF P 0-00 Up to 8 zones: maximum of 7x REHAU RF A 0-00 Up to zones: maximum of x REHAU RF D 0-00 REHAU RF M 0-00 REHAU RC 0-00 Minimum: x Maximum: x Communication distance: Up to 0m inside building and 00m line of sight

17 SUPPY 0VAC BOIER B B X-REAY C C SEC. PUMP 0VAC SUPPY 0VAC 6 HERMA ACUAORS HERMA ACUAORS 6 BOIER B B C C 0VAC DISPAY EX. SWICH I O IK DIP SWICH 6 HERMA ACUAORS HERMA ACUAORS DISPAY EX. SWICH I O IK O OFF SUPPY SESOR APP SESOR DIP SWICH HERMOSA BUS HERMOSA BUS SRIG UMBER (-F) C B A F E D C B A F E D Y X MIXIG VAVE 0-0V Y X MIXIG VAVE V AC UI UMBER (-9) FIXED flow temperature control fixed temperature mixing options..8 Wiring BA Controller SUPPY 0VAC BOIER B B X-Relay SEC. PUMP VO FREE 0VAC C High imit emperature Stat (HS). Electrical Connections of Secondary Pump Via High imit emperature Sensor BA Controller (Main Control) SRIG UMBER (-F) UI UMBER (-9) O OFF SUPPY SESOR HERMOSA BUS MIXIG VAVE 0-0V APP SESOR HERMOSA BUS MIXIG VAVE V AC SUPPY 0VAC BOIER B B X-Relay SEC. PUMP VO FREE 0VAC High imit emperature Stat (HS) Brown Blue Green & Yellow Compact mixer connection block UFH Circulation Pump. Compact Mixer Wiring 6 Compact Mixer Wiring to the BA Controller

18 I C B A RJ EWORK BUS EWORK BUS ADD-O MODUE WIREESS RECEIVER Zone Valve wiring connections for Volt Free boiler Switching Zone Valve wiring connections for 0v boiler Switching BA Controller (Main Control) Switch ive o Boiler SUPPY 0VAC BOIER B B X-REAY VO FREE SEC. PUMP 0VAC Switch ive o Boiler SUPPY 0VAC BOIER B B X-REAY SEC. PUMP VO FREE 0VAC Grey wire should taken to the connector of the volt free supply and connected Wires to Pump and Zone Valve Wires to Pump and Zone Valve SUPPY 0VAC BOIER B B X-Relay SEC. PUMP VO FREE 0VAC S P Wires to HS S P Wires to HS See Insets for Zone Valve / Boiler wiring options he wiring instructions supplied within the control equipment should be used for correct wiring. he above wiring diagram is for guidance only and should not be used as a definitive wiring diagram S P S P C High imit emperature Sensor (HS) Port Zone Valve. Electrical Connections from zone valve to boiler Via High imit emperature Sensor BA Controller (Main Control) SRIG UMBER (-F) UI UMBER (-9) DIP SWICH O OFF F E D 8 DIP SWICHES O SUPPY 0VAC BOIER B B C X-REAY C SEC. PUMP 0VAC 6 HERMA ACUAORS HERMA ACUAORS SUPPY DISPAY SESOR EX. SWICH O IK APP SESOR HERMOSA BUS HERMOSA BUS MIXIG VAVE 0-0V Y X MIXIG VAVE V AC OFF Ensure that DIP is turned on and DIP 6 is turned off to enable the function of high limit zone valve X - REAY E SUPPY 0VAC BOIER B B X-REAY C C BUE GREE/YEOW SEC. PUMP 0VAC BROW E ZOE VAVE FOW WAER EMPERAURE SESOR APP SESOR O BE SRAPPED O HE PIPE WORK (FOW) AFER HE ZOE VAVE he wiring instructions supplied within the control equipment should be used for correct wiring. he above wiring diagram is for guidance only and should not be used as a definitive wiring diagram. Connecting for separate high limitation to the BA Master Controller 7

19 C B A F E D FIXED flow temperature control fixed temperature mixing options BA Master Controller (Main Control) O DIP SWICH OFF HERMA ACUAORS 7 8 SUPPY DISPAY SESOR HERMOSA BUS MIXIG VAVE 0-0V Y X SUPPY 0VAC BOIER B B C X-REAY C UFH PUMP 0VAC HERMA ACUAORS EX. SWICH APP I O SESOR HERMOSA BUS MIXIG VAVE V AC ink EX. SWICH I O SUPPY 0VAC BOIER B B X-Relay VO FREE SEC. PUMP 0VAC 0V Boiler output signal BOIER B B Potential free boiler output signal 0V Output signal to control secondary pump for UFH system Connection from BMS timed output or external time switch he connections are volt free. Do not apply a voltage to the EX SWICH as this will damage the unit. Remote start terminal of boiler. Intergrating BMS with REHAU Intelligent Controls 8

20 .0. Fixed Flow temperature control emperature safety options Recommended Position for HS ZV MV IV CP IV IV HS UFH - Flow AC UFH - Return UFH - Manifold 6. Recommended Position of HS (-Port) valve.. High imit Sensor (HS).. Working Principle he sensor of the high limit sensor (HS) monitors the mixed flow temperature. his is a safety device, which should be set to a temperature of ºC above the max. design flow temperature. In the case of a system malfunction and the max. design flow temperature being exceeded, the high limit sensor (HS) switches off the secondary circulating pump (CP), and cuts the power to the zone valve. With the zone valve closed and the circulating pump stopped, no hot water can enter the floor heating circuits. Fitting (Always read and follow instructions supplied with components) - If a REHAU compact mixer unit is used, the high limit sensor (HS) is already pre-assembled - Check high limit is set for C above required set point - For all other systems the high limit sensor (HS) must be fitted after the circulating pump (CP) and before the manifold flow header. It should also be fitted at least 0.m to 0.m after the mixing valve... Dew Point Control he dew point control of the system is performed by the BA Master Controller coupled with the Humidity sensors positioned within the index rooms (refer section.). he controller will calculate the dew point temperature based on the index room temperature and the % of relative humidity within the IVindex room. IV If the system has more than one humidity UFH - Flow ZV HS S sensor installed within the control system then the BA Master Controller will operate to CP UFH - Manifold IV AC the worst case temperature and humidity conditions. If the cool UFH water - Return temperature flowing MOV into the floor heating/cooling circuit approaches the dew point temperature (safety factor of C), the controller will signal the actuators present on the manifold to close the return valve of the circuits and there by preventing the formation of any condensation... Installation Required Components High imit Sensor (strap-on or phial pocket/well) Qty x Supplied by REHAU Yes Wiring o wiring work is required if a REHAU Compact Mixer Unit is used. All other Systems: - he pump live (brown) wire should be connected to terminal () within the HS - he -Port zone valve live (brown) wire should also be connected to this terminal - he live (Brown) wire to the high limit sensor is connected to terminal (C) within the HS and must be supplied from the terminal of the sec pump connection inside the control centre. (As shown in Fig. ) ote: Please refer to page 6 for wiring diagram. Data Strap on: Dimensions : 9mm x 8mm x 77mm (H x W x D) Setting range : ºC to 9ºC Switch type : SPD Switching Differential : Adjustable from K to 0K Max Ambient emperature : 70ºC 9

21 .0. FIxEd Flow temperature control -PoRt ZonE valve (Zv).. Working Principle he -Port zone valve (ZV) has a dual function: - o separate the fl oor heating system hydraulically from other systems supplied by the same heat source, such as the domestic hot water system (DHWS) or radiators - Close down the fl ow of hot water from the boiler in case of a boiler malfunctioning. he -Port zone valve (ZV) makes it possible to integrate the fl oor heating with the other systems by employing the 'S- Plan confi guration, which is well established in the heating industry. Only when there is a demand signal from any of the room sensors will the zone valve be open and allow warm water to enter the fl oor heating circuits. In combination with the high limit sensor, the valve provides additional safety in case the water supply temperature exceeds a pre-set limit. If the high limit sensor cuts the power to the zone valve motor, the in-built spring closes the valve and creates a hydraulic barrier. his means the boiler pump or any other pump can no longer inject water into the fl oor heating system. Data Size : mm or 8mm Overall Dimensions : 0mm x 60mm x 9mm (H x W x )* Voltage Rating : 0V AC, 0Hz Switch Rating :.A Switch ype : Single Pole Single hrow (SPS) mm Single Pole Double hrow (SPD) 8mm Power Consumption : 6W imings (ominal) : O : seconds: under power OFF: 6 seconds: under spring return Ambient emperature Range : 0ºC maximum Flow emperature : ºC to 88ºC Max Pressure : 0. bar differential for close off 8.6 bar static Auxiliary Switch :.A at 0/0V AC at 0Hz Flow Direction : As per Arrow on valve body Electrical Connections : m Flying lead (heat resisting cable) * dimensions are approximates only 0

22 .0. Fixed Flow temperature control -port Zone valve (ZV).. Installation Supplied Required Components Qty by REHAU -Port Zone Valve of correct size x Yes Compact Mixer Unit BV HS UFH - Flow CP AC UFH - Return ZV IV Fitting (always read and follow instructions supplied with components) - he valve should be installed without blocking any vent or cold feed when closed - Positioning the zone valve (ZV) at an angle is possible, but it must Port Mixing Valve not be mounted so that the powerhead is below the horizontal level of the pipework IV IV UFH - Flow ZV HS S - For recommended positions refer to CP Fig. 7. MOV IV AC UFH - Return UFH - Manifold Port Mixing Valve UFH - Manifold If fitted in a confined space, sufficient ventilation must be available to keep the valve within its ambient temperature range. Also access must be provided to remove the powerhead if necessary. ZV MV IV CP IV IV HS UFH - Flow AC UFH - Return UFH - Manifold 7. wo locations of zone valve: Compact mixer, -Port mixing valve

23 .0. REHAU IntEllIgEnt HEAtIng/coolIng control SYStEM components overview.. Components Overview Heating Component REHAU BA, Master Controller Article number -00 (V) Constant emperature he REHAU BA Master Controller is suitable for connecting up to 8 zones of multiple sensors and V actuators. In addition it provides outputs for the FH secondary pump, main pump and boiler demand signal. Add On, Module -00 (V) he Add On Module provides another 6 zone connections. A maximum of extension modules can be used with the BA to increase the zones up to a total of zones. REHAU C, Programmable Room Sensor (V) he /7 clock combined with the -event timer enables the end user to customise his heating system according to his requirements with an adjustment range from ºC to ºC. he control sensor is also able to set the set point temperature for multiple other sensors (except another control sensor). REHAU P, amper Resistant Sensor (V) his room sensor is the ideal solution for public areas where unauthorised adjustments are to be prevented. REHAU A, Standard Sensor (V) his room sensor offers local temperature adjustment of ±ºC from the current set point of zone temperature. REHAU M, Comfort Sensor (V) his room sensor offers identical features to the REHAU A sensor. In addition it has a slide switch to enable the end user to manually switch the zone into one of modes: Auto, Day, ight and Frost Protection. REHAU D, Sensor with fl oor sensor 6-00 (V) his room sensor has identical features to the REHAU M sensor. In addition it comes including a fl oor sensor with m cable which can be used to prevent the fl oor surface temperature to either drop below a pre-set minimum or rise above a pre-set maximum temperature. Actuator 9-00 (V) he actuator allows individual control of circuits by opening and closing the corresponding isolating valve on the manifold.

24 Component REHAU Remote Air Sensor Article number (V) Remote air sensor works only in conjunction with a M thermostat. (Also available in Brass/Aluminium, please contact sales offi ce REHAU Seperate Floor Sensor 8-00 he seperate fl oor sensor works only in conjunction with a C Programmable Room Sensor or D sensor. et Extension kit (V) If the distance between the master and the Add On Module exceeds 0.m, then net extension kit is required. his includes connector blocks each with small cables with RJ connectors. REHAU C / HW, Hot Water Controller 0-00 (V) his /7 clock combined with the -event timer enables the user to customize his domestic hot water according to his requirements. It is provided with a remote fl ow temperature sensor which is strapped on to the domestic hot water supply pipe from the cylinder (within 0mm of top of cylinder) REHAU C / wo Stage Controller REHAU C / R Radiator Controller (V) 0-00 (V) his wireless /7 clock combined with the -event timer enables the user to customize his room temperature according to his requirements. his wireless room controller provides two stage control of a designated area or room which may be part of an underfl oor heating system. hese units are used where a secondary heat source is employed to boost the temperature within the area if the conventional heating system is not powerful enough his /7 clock combined with the -event timer enables the user to control the temperature of a circuit or Zone of Radiators that are hydraulically independent from an underfl oor heating system. For more information refer to section., see page. V Relay High imit Sensor As the thermal actuator outputs on the Master Controller and Add On Module are volt ac, there is sometimes a need to convert these to be able to switch 0 volt i.e. for connecting a zone valve, dehumidifi er etc. A Relay module R-- SP can be used on thermal actuator output H to 8 on Master Controller, H 9 to on the Add On Module. he relay is designed to operate a switching current of up to Amp and is fi tted with green indicator lamp to signify operation. -00 Over temperature thermal cut-out device with auto reset.

25 .0. REHAU IntEllIgEnt HEAtIng/coolIng control SYStEM components overview.. Additional Components Overview Heating/Cooling Component BA Cooling Kit Article number 0-00 (V) he BA Cooling Kit contains a humidity sensor, WAC switch and a fl ow temperature sensor. his kit when integrated into the system helps prevent the fl ow of water temperature below the dew point ( in cooling mode) and there by prevent condensation... Components Overview Wireless Sensors/Controllers Component REHAU RC, Wireless Receiver Article number 0-00 (V) he wireless receiver is required to receive signals from wireless sensors/controllers. Max distance between the Master/Add On Module and receiver is m. Communication distance of up to 0m inside building and 00m outside building. REHAU RF C, Programmable Room Sensor REHAU RF P, amper Resistant Sensor (V) 0-00 (V) he wireless /7 clock combined with the -event timer enables the end user to customise his heating system according to his requirements with an adjustment range from ºC to 0ºC. he control thermostat is also able to set the set point temperature for multiple other thermostats (except another control sensor). ot used if cooling is to be utilised. his wireless room sensor is the ideal solution for public areas where unauthorised adjustments are to be prevented. REHAU RF A, Standard Sensor 0-00 (V) his wireless room sensor offers local temperature adjustment of ± ºC from the current set point of zone temperature. REHAU RF M, Comfort Sensor 0-00 (V) his wireless room sensor offers identical features to the REHAU A thermostat. In addition it has a slide switch to enable the end user to manually switch the zone into one of modes: Auto, Day, ight and Frost Protection. REHAU RF D, Floor imit Sensor 0-00 (V) his room thermostat has identical features to the REHAU M thermostat. In addition it comes including a m long sensor which can be used to prevent the fl oor surface temperature to either drop below a pre-set minimum or rise above a pre-set maximum temperature. REHAU RF C / HW, Hot Water Controller 0-00 (V) his wireless /7 clock combined with the -event timer enables the user to customize his domestic hot water according to his requirements. It is provided with a remote fl ow temperature sensor which is strapped on to the domestic hot water supply pipe from the cylinder (within 0mm of top of cylinder).

26 Component REHAU RF C / R, Radiator Controller Article number (V) his wireless /7 clock combined with the -event timer enables the user to control the temperature of a circuit or Zone of Radiators that are hydraulically independent from an underfl oor heating system. For more information refer to section., see page. REHAU RF C /, wo Stage Controller (V) his wireless /7 clock combined with the -event timer enables the user to customize his room temperature according to his requirements. his wireless room controller provides two stage control of a designated area or room which may be part of an underfl oor heating system. hese units are used where a secondary heat source is employed to boost the temperature within the area if the conventional heating system is not powerful enough.

27 .0. wireless SEnSoRS/contRollERS working PRIncIPlE raditional O/OFF control Advanced PI- control 0.ºC OFF 0.0ºC 9.ºC HEA 00% O PI- control gives a more stable and accurate room temperature - for higher comfort levels. he graph above left shows the hunting temperature profi le of a room with a traditional sensor. he graph above right shows the stabilising effect of the PI controller, improving comfort and saving energy. 8. Pi-Control of room temperature his sophisticated electronic control system was designed specifi cally for fl oor heating applications in the residential and light commercial sectors. he room sensors are designed to control the indoor comfort temperature with a high level of accuracy. he sensors communicate with the REHAU BA controller using a bus protocol, which reduces the wiring of the components to a minimum whilst the range of sensor types allows greater fl exibility in control system layout and can meet the requirement of most projects. 0.mm wo-core cable is recommended for connecting the system in either star or series (daisy chain) confi gurations. Standard installation cable (mm² twin) can be used if required. he low voltage (v) bus system makes it possible to install the room sensors in almost every environment whilst always providing maximum safety. he temperature requirements of each heated zone on the system is communicated to the controller unit of the system, i.e. to the REHAU BA for fi xed fl ow water temperature. he master control units will then control the operation of circuit actuators, main system pump, secondary pump and the boiler switching. Proportional Integral Control Sensor he REHAU controller utilises PI Control, this is designed to cover a broad range of specifi cations. he system uses self learning capabilities to continue optimisation throughout its operation. After approximately 0 days, depending on the number of operations, the system should reach optimal output levels for given conditions. Advantages of this form of control are that, after a short period, the controls determine the optimum time to open the actuators, allowing the room to reach the set temperature with minimum overshoot. his gives high comfort levels while ensuring minimum wasted energy. Hunting behaviour, a characteristic associated with traditional sensors, causes the on-off cycling of the boiler when searching for the set temperature; this can result in excessive wear and tear on components. REHAU PI control eliminates the hunting behaviour and can help to increase the cycle life of all system components. he integration of the system into the S plan control confi guration is also possible. 6