Polypipe Under Floor Heating Systems Technical Installation Manual

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TIG1 JULY 2009

EFFECTIVE: 1ST JULY 2009

Under Floor Heating Systems

Technical Installation Guide

July 2009

Technical Installation Guide

Under Floor Heating Systems

Polypipe Building Products

Broomhouse Lane

Edlington

Doncaster DN12 1ES

Tel: 01709 770 000

Fax: 01709 770 001

2410 London Road

Mount Vernon

Glasgow G32 8XZ

Tel: 0141 778 8822

Fax: 0141 778 2703

Dromore Road

Lurgan, Craigavon

Co. Armagh BT66 7HL

Tel: 028 38 881270

Fax: 028 38 882344

www.polypipe.com

Under oor heating systems trade website: www.ufch.com Under oor heating systems consumer website: www.freeyourwalls.com

Polypipe oor heating products, excluding manifolds and control products, are covered by a 50 year guarantee*, which protects against defects in materials or manufacture of the heating system from date of purchase. This guarantee only applies if the system is installed in accordance with the manufacturer’s recommendations contained within the Technical Installation Guide (the latest version of which can be found at www.ufch.com), and is used in a normal domestic operation. This document should be read in conjunction with all other documentation supplied with Polypipe products.

If you have any queries please contact our Technical Department on 01709 770000.

*Full terms and conditions for Polypipe heating products 50 Year Guarantee are available at www.ufch.com

CONTENTS

How to use this guide ............................................................................................................03

INTRODUCTION

About Polypipe ......................................................................................................................04

An overview of under oor heating systems ...........................................................................06

Selecting the right Polypipe under oor heating system ..........................................................07

System selection ....................................................................................................................08

Design service ........................................................................................................................09

Guide to oor coverings for under oor heating systems ........................................................10

INSTALLING THE SYSTEM

Solid Floor ..............................................................................................................................12

Floating Floor .........................................................................................................................16

Suspended Floor ....................................................................................................................18

Modular Heating Panel ..........................................................................................................22

Overlay™ ...............................................................................................................................28

Overlay™ Lite ........................................................................................................................36

CONNECTING & CONTROLLING THE SYSTEM

Connecting to heat source .....................................................................................................38

Manifolds ..............................................................................................................................39

Water temperature controls ...................................................................................................40

Room temperature controls ...................................................................................................41

Single room applications ........................................................................................................44

System commissioning ...........................................................................................................46

TECHNICAL DATA

Heat output tables .................................................................................................................48

General system information ...................................................................................................49

FAULT FINDING CHARTS

Hydraulic fault nding chart ...................................................................................................50

Electrical fault nding chart (master connecting box) ..............................................................51

STANDARDS

Accreditations, standards and guarantees ..............................................................................52

FORMS

1-2-3 Product selection form ..................................................................................................53

Design enquiry form ..............................................................................................................54

LITERATURE

Other information and literature ............................................................................................55

02 03

HOW TO USE THIS GUIDE

Important notice: This publication is provided as a comprehensive guide on how to install Polypipe

under ﬂoor heating systems. It is an important document as we cannot accept any liability, or honour any guarantee, for products and systems that have not been installed in accordance with our published instructions.

From time to time our installation advice may be updated at which time previous printed copies will become out of date. The latest version of our installation advice, including a downloadable version of the current Technical Installation Guide, can be found at our trade website, www.ufch.com

Selecting the right system

This guide is intended for competent trained plumbing and heating installers and we assume that you will have already specied your system of choice before consulting this publication for installation advice. Basic information on selecting the right system is provided in this guide. For more detailed guidance refer to our Design & Specication Guide or visit our trade website at www.ufch.com or consumer website at

www.freeyourwalls.com

Navigating the Technical Installation Guide

Having read the general introductory sections at the front of the guide, ensure that you have selected the correct system for your oor type and project. Read the guide to oor coverings to ensure that your system is compatible with your oor type.

Next, choose your selected under oor heating system type from the section “Installing the system” and follow the step by step instructions. Everything should be straightforward but remember that the Polypipe Technical Support team is always ready to help answer any questions you may have.

Whichever Polypipe under oor heating system you are installing you will need to refer to the information provided in the section “Connecting and controlling the system”. This section provides all you need to know about manifolds and controls, connecting your system to an appropriate heat source and commissioning the system.

Technical data

Towards the back of this guide you will nd technical data such as heat output tables, pipe data and general system information as well as useful forms to use with our Product Selector and System Design Service.

Additional information

Should you have any questions at any time, or require any kind of technical support call our Technical Support team on 01709 770000.

Online assistance is available at www.ufch.com, our comprehensive website for installers, developers and merchants. As well as information on technical advice and product benets, you can nd useful case studies and details of Polypipe stockists. Video instructions on under oor heating installation are also available to view.

04 05

ABOUT POLYPIPE UNDER FLOOR HEATING

Easy installation

Polypipe under oor heating systems have been designed with ease of installation in mind. Innovative product designs ensure minimal disruption to existing heating and electrical supplies during installation. As our systems are compatible with standard central heating boilers, connectivity is also streamlined. Polypipe under oor heating systems can be installed up to 20% quicker than radiators.

Polypipe under oor heating systems are installed in one stage, eliminating the need for a time consuming second x. Under oor heating components are much easier to manoeuvre on site than large, bulky radiators; reducing handling issues and potential damage. Unlike radiators, there is also very little theft value during installation.

Details of each type of Polypipe under oor heating system can be found on page 6.

Maintenance free

Once installed, a Polypipe under oor heating system is virtually maintenance free. There are no joints in the pipe work within the ooring, signicantly reducing the possibility of leaks. Polypipe under oor heating products are subjected to rigorous testing and meet a number of exacting standards, full details of which can be found on page 52. All our manufacturing processes are monitored and controlled in accordance with the international quality standard BS EN ISO 9002.

Choosing under oor heating also eliminates a number of general maintenance and decoration requirements, normally associated with radiators, such as painting the radiator or removing it to paint the wall.

Demonstrating the utmost condence in product performance, and providing our customers with peace of mind, Polypipe under oor heating systems are covered by the Polypipe 50 year

guarantee (full details can be found at www.ufch.com).

Easy to control

Polypipe manufactures a range of water and room temperature control solutions, allowing you to source a complete, integrated system from a single supplier. The range includes a number of control products, with options to suit a variety of lifestyle patterns, and the abilities to control different rooms independently.

Full details of Polypipe control products can be found on pages 40 to 43.

Flexible approach

Polypipe under oor heating systems use the exibility of polybutylene pipe to provide a solution for all house and room types. We also have a range of unique and innovative products, including the Zonal Regulation Unit (ZRU) which is an excellent enabler allowing under oor heating systems to be incorporated into single rooms or refurbishment projects with minimal disruption to existing heating and electrical supplies.

For more information on our single room applications see pages 44 and 45.

Excellent service

At Polypipe we understand that selecting the right solution for each application involves detailed consideration. This is why we offer extensive customer service support, including free system design and full technical support if any problems arise. We want to ensure that your installation runs smoothly from the beginning and our technical support staff can assist you with any questions you might have.

During installation we offer:

• Pre-project training at one of our training centres

• Pre-project training by distance learning

• On-site assistance

We also provide an extensive back up service:

• Technical representation available to discuss systems in general and particular projects

• www.ufch.com

• Technical Installation CD

• Specialist Technical Hotline on 01709 770000

Energy efﬁcient

Under oor heating systems can be more economical to run than radiator based systems. As they demand a low temperature rise output from the boiler, they are ideally suited to achieving maximum economy from a condensing boiler or heat pump. However, they are just as efcient with higher temperature heat sources, for example solar and solid fuel, where the correct water temperature can be set at the point of distribution.

Polypipe is one of Europe’s largest manufacturers of specialist plastic plumbing, heating, waste and drainage products.

Our market leading under ﬂoor heating product range has been continuously developed and improved with frequent innovative additions, the latest of which are Modular Heating Panels (MHP) - a revolutionary solution for suspended ﬂoor applications - and Overlay™ Lite, a lightweight ﬂoor panel to complement our innovative over ﬂoor heating range.

Polypipe is a member of the Underﬂoor Heating Manufacturers’ Association (UHMA), who set and enforce standards for materials, design and installation of under ﬂoor heating systems - standards that we embrace within every aspect of our range.

Polypipe under oor heating systems have been designed with speciers, installers and users in mind.

Our systems combine ease of installation with reliable long-term performance, and we hold a range of stock ready for prompt dispatch. Unique to the Polypipe service proposition is our room and house packs concept. Recognising that under oor heating systems are difcult to specify using individual components, we created a range of over 300 pre-set combinations that can be ordered as complete kits. By simply specifying key variables such as oor type, room size, control and circuit data the right pack can be specied in minutes. It’s as easy as . We have even created a unique online product selection tool.

Following recent innovative product introductions, we have categorised our range into 3 groups in order to make selecting even more instinctive:

With a long established reputation for product quality and value, backed by our strict trade-only distribution policy, Polypipe has become the clear leader in the under oor heating category. Recent innovations ensure the Polypipe range is the widest available from a single manufacturer, including traditional under oor heating systems for every oor type as well as the innovative MHP and Overlay™ products.

Polypipe under oor heating systems are ideal for every application, including new build, self build, renovation and home improvement projects. Whole house, single oor and single room projects are equally catered for in our extensive product offering. Whatever job you are undertaking, Polypipe has the product to suit.

Polypipe is a recognised and respected brand, and is well established as the system of choice for domestic homes by many installers. All Polypipe under oor heating systems are supplied as a complete system, and require no additional components for installation. Polypipe under oor heating systems are rigorously tested, and comply with (or exceed) all relevant UK standards. We use an integrated exible plumbing system, incorporating polybutylene pipes and a range of pusht ttings. The systems are also designed for use with copper pipes, allowing the integration of rigid pipes when necessary.

OVERLAY™

LITE

OVERLAY™

SOLID

FLOOR

FLOATING

FLOOR

06 07

AN OVERVIEW OF UNDER FLOOR HEATING SYSTEMS

SELECTING THE RIGHT POLYPIPE UNDER FLOOR HEATING SYSTEM

Polypipe has the widest available range of under ﬂoor heating systems, with a product available for every conceivable ﬂoor type or residential heating project. With Polypipe, under ﬂoor heating is not restricted to new build developments or self build projects. Our unique Overlay™ product is particularly well suited to single room projects such as kitchens, bathrooms, conservatories, extensions and loft conversions. Polypipe Modular Heating Panels (MHP) were developed to provide an innovative and practical solution to installing under ﬂoor heating into upper ﬂoors.

The notes below provide a brief overview of the methodologies employed to install under oor heating systems for various oor types. Refer to the overview on the page opposite. Full installation instructions for each oor type can be found in the section titled ‘Installing the system’ on pages 12 to 36.

Solid Floor

Polypipe under oor heating can be permanently built into solid concrete or screeded oors. As required by current Building Regulations, insulation is built into the oor directly beneath the unique Polypipe lightweight plastic oor panel. The heating pipe is simply slotted into the panel and then permanently covered by the screed. Suitable for all oor coverings, solid oor systems can incorporate 15mm or 18mm pipe.

The oor panels form a simple grid for the quickest possible pipe laying and provide a precise guide to achieve the minimum bending radius. Panel

castellations are set at exact centres and

hold the pipe against movement when screeding. The oor panel holds the pipe above the insulation allowing full screed surround. Optimum screed depth is 65mm from the panel base, i.e. 40mm from the pipe top. Insulation below and at the edges of the oor screed is required by Building Regulations. Edge insulation also acts as an expansion joint.

Floating Floor

When installed in oating oors, Polyplumb pipe is simply pressed in to the pre-formed heat spreader plate, which sits in grooves within the oating oor insulation panel. The oating oor system is then covered with 18mm chipboard sheeting. Suitable for all oor covering, oating oor systems can incorporate 15mm or 18mm pipe.

Suspended Floor

For installations in suspended oors, Polypipe under oor heating uses double heat spreader plates. Alternatively, pipes can be laid on top of insulation between joists. Standard tongue and groove oorboards are laid on top of the system. Suspended double heat spreader plate systems use 15mm pipe.

MHP (Modular Heating Panels)

Modular Heating Panels offer a revolutionary new way to solve the issue of installing under oor heating into upper oors. MHP is available in two widths and two lengths to t all standard joist spacings. All components and circuitry is pre-congured into the panels which are simply installed between the joists, linked together and connected to the manifold.

Overlay™

Overlay™ allows under oor heating to be installed into existing spaces quickly, easily and practically. The unique system is supplied with a choice of patented low prole panels to suit all types of oor coverings. The Overlay™ system is laid over existing solid or timber oors.

Under ﬂoor heating systems

Product selection: Typical applications and features

New build Existing ﬂoor

SUSPENDED

FLOOR

Under ﬂoor

All ﬂoor coverings

High mass system

Typical ground ﬂoor or beam and block construction

All ﬂoor covering except natural wood/thick laminates

Lightweight construction

No wet trades required

Lightweight ﬂoor coverings

Larger areas

Multiple rooms

Tiles or natural wood

Wet areas

Over ﬂoor

MODULAR

HEATING

PANEL

All ﬂoor covering

Fit from above

Traditional joists

Traditional heat source

All ﬂoor coverings

Fit from above/below

Traditional or engineered joists

Traditional or renewable heat sources

SUSPENDED

FLOOR

08 09

SYSTEM SELECTION

Our comprehensive system design service includes:

• System design, including heat loss calculations for residential applications

• Circuit lengths

• Circuit pressure losses and velocities

• Flow rate settings per circuit

• Full product material specication

Installation service

• Pre-project training at training centre

• Pre-project training by distance learning

• On-site assistance if required during project installation

Backup service

• Technical representation available to discuss systems in general and particular projects

• Web-site and information on CD

• Specialist Technical Hotline on 01709 770000

Polypipe has removed the mystique from specifying the correct under ﬂoor heating solution for a given project and the need to calculate all of the individual components required. Our unique Product Selector, which is available on page 53 or online at www.ufch.com, uses a simple 3 step process to calculate your requirements using basic project data that you provide. The system includes details of over 300 pre-conﬁgured system kits that contain all of the parts and components you need. Once you have determined the correct pack for your project it can be ordered under a single item code via your merchant.

DESIGN SERVICE

For projects that fall outside the scope of the room packs or house packs, Polypipe offers a fully bespoke system design service. To utilise this facility, simply complete the enquiry form on page 54, or at www.ufch.com, and submit your drawings to Polypipe. You will then receive a complete design and component list for the project.

To use the Polypipe Product Selector you rst decide whether the project is a single room, a whole house solution, or requires a bespoke design. You then simply input data for each room, providing oor type, room size, and control zones to calculate the required pack.

All packs have a single order code and include all the necessary ooring materials, pipe, distribution (manifolds, ZRU, etc.), water temperature and room temperature controls.

To select the appropriate solution, choose from the following options:

Room Packs

Room packs are designed for single room applications: i.e. kitchens, bathrooms, conservatories, loft conversions and extensions. This range of under oor heating packs contain all the ooring and control equipment required for a single project, in solid oor, our traditional Overlay™ and our NEW Overlay™ Lite systems. All room packs have a maximum heat output of 100W/m

House Packs

House packs provide you with a quick and easy way to select and order from our range of under oor heating products, without the need to submit a design. The packs are designed for solid, oating or suspended (double heat spreader plate) projects.

Packs can be applied to all new build or renovation properties that fall into the following criteria:

• Rooms requiring up to 70W/m

• Properties built to current Building Regulations

• Projects where the manifold can be positioned within 6m of the room entrance

Design services

Modular Heating Panels

Our revolutionary new MHP panels, designed to make under oor heating easier to install between ceiling joists for upper oor suspended oor applications, have their own product selector, which is also available online at www.ufch.com

10 11

GUIDE TO FLOOR COVERINGS FOR UNDER FLOOR HEATING SYSTEMS

Under ﬂoor heating systems will work efﬁciently with any ﬂoor covering, as long as it is well insulated underneath. However, each covering has different thermal conduction properties, and harder surfaces offer better conductivity and, therefore, better heat output rates. The following notes provide some guidance on each type of covering.

Vinyl

Suitable for all Polypipe under oor heating systems:

Sheet vinyl is sensitive to long term exposure to heat. There are two categories of vinyl; one is limited to constant temperatures of around 26°C and the other to 30°C. Check the oor surface temperature indicated by your vinyl supplier for compatibility with under oor heating. If unsure contact the Polypipe hotline or the vinyl oor manufacturer.

Laminate

Suitable for all Polypipe under oor heating systems:

Laminate ooring should be laid on roll type oor leveller, rather than the rigid panel type. Movement that occurs must be accommodated by an expansion gap around the oor deck.

Timber

Suitable for Polypipe solid oor and suspended oor systems:

Concerns regarding the effect of heat on a timber oor are misplaced. The more important issue is the oor moisture content. Timber oors should be laid at a moisture content of 10-11%, which when heated will reduce to 8-9%, and cause only a very small amount of shrinkage. The oor will re-absorb some moisture when the heating is not operating and the moisture content will increase to 12-13%. Further details on installing timber oors over Polypipe under oor heating systems can be found on page 15.

Carpet and underlay

Suitable for all Polypipe under oor heating systems:

The nature and thickness of the carpet underlay is fundamental in determining good heat transfer. The most popular underlay type is sponge with a wafe pattern moulded into the underside. These allow good heat transfer. Felt and rubber crumb underlay should be avoided. These products can seriously reduce the effectiveness of an under oor heating system, as they insulate the oor surface and prevent heat transfer.

The TOG value of carpet and underlay should be available from the respective manufacturer. For optimal system performance choose an underlay with a maximum TOG value of approximately

0.5. The maximum TOG value of carpet should be approximately

1.0 to 1.5.

Stone and ceramic tiles, marble or ﬂagstones

Suitable for all Polypipe under oor heating systems:

These types of oor nishes are usually cold underfoot. However, with oor heating they are transformed into warm comfortable surfaces. Each of these nishes is essentially brittle and it is imperative that the design of the supporting oor structure is stable and rigid to prevent cracking. It is recommended that exible adhesives and grout be used.

Pre-installation requirements

The sub oor must be swept clean and be free from mortar residues.

Installation

Fitting Insulation

Step 1:

In accordance with Part ‘L’ of the current Building Regulations,

a suitable layer of insulation material should be included within

the oor construction. It is the responsibility of the Architect or

Builder to ensure compliance. However, in all instances insulation

must be installed beneath the under oor heating system in order

to ensure that any downward heat loss does not exceed 10W/m

in accordance with BS EN 1264.

Fitting the edge insulation strips

Step 2:

Using edge insulation strip allows the free expansion of the oor

screed. The insulation strip should be installed around all perimeter

walls and xed constructions such as columns, steps and access doors.

Edge insulation strip is bent at 90° near to the base to form

a double sided self-adhesive strip which bonds the oor plates

to the oor insulation. Edge insulation strip should be tted in

addition to perimeter insulation required by Building Regulations.

Fitting the ﬂoor panels

Step 3:

The oor panels are laid over the pre-installed insulation and

should be overlapped at the edges.

NOTE: The ½ castellation should overlap the ¾ castellation. The rst

panel should be laid with the ½ castellation edge against the wall.

Panels can be cut by simply using a saw or snips or it can

be overlapped to the nearest castellation t.

Floor panels should not be used at the base of the manifold

as pipes need to be closer together than the oor panels allow.

Pipes around this area should be secured using pipe clips which can

also be used intermittently to secure the clip plate to the insulation.

When a pumped (liquid) screed is to be used it is essential that all of

the panel joints are made correctly and that no panels are allowed to

simply ‘butt-up’ as this may allow the screed to penetrate below the

under oor heating system and cause the panels to rise up. Similarly

the panels should be rmly secured around the perimeter of the room

using staples so as to prevent possible risk of the panels lifting.

Preparing the pipe

Step 4:

You will need to remove the coil from the bag, leaving the shrink

wrap on, uncoiling from centre of the coil.

Laying the pipe

Step 5:

Once you have completed laying the solid oor panels the pipe

can be tted starting at the manifold position in line with the

pre-designed centres. 15mm and 18mm pipe can be laid

at 100mm or 200mm centres as required, 18mm pipe can also

be laid at 300mm centres.

The minimum bend radius is achieved by encircling two

castellations for a 90° bend or three castellations for a 180° bend

(see diagrams on next page).

12 13

SOLID FLOOR

Key design and installation information

Material requirements (approx)

Maximum heat output Approx. 100W/m

Recommended design ow temp 50°C Maximum circuit length 100m (15mm pipe)

120m (18mm pipe) Maximum coverage per circuit 12m2 at 100mm centres

22m2 at 200mm centres 30m2 at 300mm centres* *(18mm pipe only)

Pipe 8.2m/m

at 100mm centres

4.5m/m2 at 200mm centres

3.3m/m2 at 300mm spacing* *(18mm pipe only)

Floor plate usage 1 plate/m2 allowing for cutting (Actual 1·2m2/plate)

Edging insulation strip 1.1m/m

Conduit pipe 2m/circuit

Polypipe under ﬂoor heating in solid or screeded ﬂoors incorporates the unique Polypipe screeded ﬂoor panel. The lightweight plastic ﬂoor panels nest for easy storage and carrying.

Polypipe has the perfect solution for installing under oor heating into solid or screeded oors. Utilising our unique lightweight plastic oor panels, which are quick and easy to cut to size, it is possible to t Polypipe under oor heating into any shaped room.

Polypipe solid oor panels form a simple grid to ensure the fastest possible pipe laying and also provide a precise guide for the pipe, ensuring that the minimum pipe bending radius is achieved.

The panels are laid above pre-installed insulation and the system includes edging insulation strip to ensure maximum performance and efciency.

Polypipe under oor heating systems can be used with the following solid oor constructions:

• Sand & cement screed (4:1 mix)

• Pumped screed systems (anhydrite, etc)

• Fine or heavy concrete

• Polymer modied screeds

Step 6:

Circuits being laid at 100mm or 200mm centres must be laid in a spiral conguration. The rst loop of pipe should be laid around the perimeter of the area to be covered by that circuit. The next loop of this circuit should be laid either 200mm from the rst loop of pipe for 100mm centres or 400mm from the rst loop of pipe for 200mm centres.

Step 7:

Continue to loop the pipe into the centre of the panels leaving enough space to form a double return (‘S’ shape in the centre of the loop).

Step 8:

Now work back out from the centre by lling the space between the inwardly spiralling loop of the primary circuit ensuring the pipe is laid at the correct spacing centres.

18mm pipe installation formation

Where 300mm centre spacing is require (18mm pipe systems only)

a meander pattern can be used. The pipe simply crosses the room

from one side to the other encapsulating 3 castellations at each

return bend.

Conduit pipe

A 400mm length of conduit pipe should be tted over the under oor

heating pipe in any situation where damage may be caused to the

pipe i.e. where the pipe passes through internal walls or doorways,

where the pipe emerges through the oor up to the manifold

or where the pipe passes through either an expansion or day joint.

Preformed long radius bends can also be used to provide a neater

solution if required.

A section of conduit pipe 400mm long should be tted around the

heating pipe where the pipe passes through the edge insulation strip,

e.g. room to room, or through expansion joints within the oor.

Conduit pipe should also be used where the pipe leaves the oor

adjacent to the manifold. This can be threaded down the pipe

after the pipework has been installed.

14 15

Expansion joint

BS EN 1264-4 recommends that an expansion joint is constructed

in stone and ceramic nished screeds for every 40m

of oor area

at a maximum length of 8m and an aspect ratio of 2:1.

An expansion joint is also required in long narrow areas such

as corridors, etc.

The image below shows a typical arrangement where the pipes

pass through either an expansion or a day joint. A strip of edge

insulation is used to provide the expansion capacity.

For further information regarding oor screeding requirements

for under oor heating systems please refer to BS8204-1 or the

BISRIA Guide: Screeds with Under Floor Heating.

Testing

Step 9:

Once the pipes circuits have been installed and pressure tested the

screed cover can be applied. Care should be taken to ensure that

the screed is tightly compacted around the pipe to ensure that no

voids are present. The system should remain under pressure (6 bar)

in order to prevent the risk of any damage being caused to the

walls of the pipe whilst the screed is being applied.

Laying the screed

Step 10:

The overall quality and thickness of a sand and cement screed

should meet the requirements of BS8204-1 which stipulates that

in domestic or light commercial applications a minimum thickness

of 65mm should be used. The thickness of alternative coverings,

such as anhydrite or polymer modied screeds, may differ depending

on construction requirements. This information should therefore

be provided by the specialist screed manufacturer/supplier.

After the screed has been laid the oor should be covered with

a membrane to retard the drying out process, particularly in warm

weather. The oor should be allowed to cure and dry naturally until

full strength is reached in accordance with relevant British Standards

and manufacturers’ instructions (approx 30 days for sand and

cement and concrete oors). Under no circumstances should the

under oor heating system be used to articially dry/cure the screed

as this could cause the screed to crack and seriously undermine

the integrity of the oor construction. Once the screed has fully

cured the under oor heating system can be switched on and the

manifold ow temperature slowly increased up to the calculated

design temperature.

Finishing

Timber ﬂoors

Many people are concerned by the effect of heat on a timber

oor, but this concern is misplaced. The important factor is the

oor moisture content.

Timber oors can be laid directly over the screed at a moisture

content of 10-11% which during the heating season will reduce

to 8-9% and may cause a small amount shrinkage.

The oor will re-absorb some moisture when the heating is not

operating and the moisture content will increase to 12-13%.

Application of timber ﬂoors over solid ﬂoor systems

Where solid oak ooring is to be laid on a solid oor, joists can

be tted at 1m centres to provide a xing point for the boards.

Insulation, solid oor panels and pipe can be laid between

the joists and screed laid level with the top of the joists

(see diagram below).

Individual circuits of pipe are then laid between each set of joists

with care being taken to ensure the screed is completely dry prior

to tting the solid oak covering (see diagram).

90° 180°

Screed Timber ﬂoor covering Solid ﬂoor plate Joist at 1m spacings

Pipe Conduit

Insulation Sub ﬂoor

Pre-installation requirements

The sub oor must be swept clean and be free from mortar residues.

Installation

Laying the ﬂoating ﬂoor panels

Step 1:

Lay the 1200 x 1200 x 50mm oating oor panels directly over the entire oor area to be heated, ensuring the panel grooves are aligned. The panels can be cut to t where necessary.

A void in the insulation is often retained around the edge of the room to allow for distribution pipes to be laid from the room to the manifold.

Laying the spreader plates

Step 2:

Single heat spreader plates that have pre-formed grooves at 300mm centres need to be laid on top of the oating oor panels. These plates ensure an even spread of heat across the oor area and hold the pipe rmly within place in the oating oor panel.

Laying the pipe

Step 3:

Once you have completed laying the oating oor panels and heat spreader plates the pipe can be tted into the pre-formed grooves of the heat spreader plate. Start at the manifold position and use the grooves in the oating oor panel to loop round the entire room.

The maximum circuit length is 80m using 15mm pipe or 100m using 18mm pipe. Pipe should be laid in the pattern shown below.

NOTE: Areas of potential high point loading, e.g. under heavy furniture kitchen units and appliances, will require additional oor support. Timber battens (50mm x 50mm) should be positioned between the oating oor panels and notched to allow the passage of pipes.

Testing

Step 4:

Once the pipe circuits have been installed and connected to the manifold the system should be pressure tested to 6 bar for a minimum of 1 hour before the timber oor covering is laid. It is recommended that the system remains under pressure whilst the ooring is laid.

Finishing

The room can then be nished by tting 18mm or 22mm tongue and groove sheets of chipboard, glued on the edge, over the oating oor system. Mark the position of the pipe where door thresholds or carpet strip are to be installed.

When laying a ceramic or stone oor covering ensure that any deection in the oor is minimised. It is recommended that a slip mat or uncoupling membrane is used rather than a second layer of wood.

The Polypipe ﬂoating ﬂoor system is designed for use in applications where a solid ﬂoor installation is not suitable due to structural weight limitations or where a ‘dry build’ ﬂoor option is required. Suitable for use in either new build or existing properties, the ﬂoating ﬂoor panels can be installed directly on top of both solid and timber ﬂoors.

The 50mm thick high density polystyrene panels have a thermal value of 0.036W/mK and can be used to enhance the thermal insulation requirement of the oor structure as required under current Building Regulations. However, care should be taken when installing oating oor panels on top of a primary insulation layer to ensure that excessive deection does not occur in the nal oor construction.

It is therefore recommended that any other insulation materials used below the oating oor panels are of a high density construction (100kN/m

@ 10% compression min).

16 17

FLOATING FLOOR

Key design and installation information

Pipe 3.1m/m2 at 300mm centres Floating oor panel 1 panel/1.4m

Single spreader plate 3 plates/m

Material requirements (approx)

Maximum heat output Approx. 70W/m

Recommended design ow temp 60°C Maximum circuit length 80m (15mm pipe)

100m (18mm pipe) Maximum coverage per circuit 25.8m2 at 300mm centres

(15mm pipe) 30m2 at 300mm centres

(18mm pipe)

Polyplumb

barrier pipe

Single heat

spreader plate

Insulated ﬂoating

ﬂoor panel

18 19

SUSPENDED FLOOR

Pre-installation requirements

Installation

Fitting nsulation

Step 1:

Before installing a suspended oor system it is necessary to insulate between the joists. Polypipe recommend that a rigid polystyrene or foam insulation material is used.

Fitting the spreader plates

Step 2:

The insulation layer should t tightly between the joists directly below the spreader plate to ensure that the spreader plate is supported and therefore remains in contact with the underside of timber oor covering. This is necessary to eliminate any air gaps or draughts between the under oor heating system and the oor.

Any other services, such as drainage or electrical wiring, should be installed below the insulation layer.

The oor joists then need to be notched or drilled in accordance with Building Regulations. This facilitates the passage of the pipe between the joist gap to allow the entry and exit of the pipe to and from the room.

The spreader plates can then be xed evenly across the joists and in accordance with your installation design.

Laying the pipe

Step 3:

Once the spreader plates have been xed in place the pipe can be tted in to the grooves in a meander pattern. It is recommended that the ow pipe from the manifold be taken to the furthest point of the room when installing the circuit as this ensures that sufcient heat is provided around the perimeters of the room.

Care should be taken when installing the pipe to ensure the spreader plates are not pushed downwards and away from the underside of the timber nished oor covering as this could lead to potential underperformance of the system.

Testing

Step 4:

Double heat

spreader plate

Pipe

Return Flow

Joists notched to

accept pipe returns

Designed for use in timber suspended or battened ﬂoors the Polypipe suspended ﬂoor system uses aluminium double heat spreader plates to transmit the heat evenly across the ﬁnished ﬂoor surface.

Suitable for joist widths of 300mm to 450mm the spreader plates are simply xed to the joist using small nails or staples. The pipe is then run in to the preformed grooves of the panels which are designed to hold the pipe securely at 225mm average centers.

A layer of insulation below the panels will ensure that almost all of the heat generated passes up in to the room.

The Polypipe suspended oor system is also suitable for use with ‘sprung’ ooring systems as used in sports halls, etc.

Key design and installation information

Material requirements (approx)

Maximum heat output Approx. 70W/m

Recommended design ow temp 60°C Maximum circuit length 80m (15mm pipe) Maximum coverage per circuit 17m2 at 225mm average

double heat spreader plates (15mm) centres

Double heat spreader plates

Pipe 4.5m/m

Heat spreader plates 2 plates/m

Ceiling

Polyplumb barrier pipe Polystyrene or foam insulation Supporting joists

Tongue & groove ﬂooring

Double heat

spreader plate

450mm

1000mm

250mm

20 21

Pipe only systems

The use of heat spreader plates is recommended, as they assist the

response time and heat dispersion. However, in some circumstances,

simply laying pipe in an air void between foil faced reective

insulation and the underside of the oorboard will be adequate.

The space between the top of the insulation and the underside

of the oor deck should be kept to a minimum (20mm) and care

should be taken to ensure that the insulation is sealed at the

edges and ends.

Pipe only applications are suitable in areas where the heating response

is less important, e.g. bedrooms, and is not recommended in living

spaces or over unheated spaces, e.g. rooms above garages.

Enhancing pipe only systems

The effectiveness of pipe only systems can be enhanced by laying

a weak (1:6) dry mix screed approximately 25mm thick between

the joists.

In order to apply this, extra support may be required below the

insulation. Although pipe only systems are designed to operate

at 60°C ow temperature, the ow temperature may be reduced

in these circumstances.

Before this system is considered it is suggested you consult

a structural engineer to conrm its suitability.

Finishing

Laying a timber ﬂoor covering

Step 5:

It is strongly recommended that the timber oor covering is laid immediately after the under oor heating pipes have been installed and pressure tested to eliminate any risk of damage to the system by other trades.

Either traditional tongue & groove oorboards or 18mm/22mm chipboard can be tted directly on top of the spreader plates. These can be xed directly through the spreader plate down in to the joists below. It is important to indicate the position of pipework in areas where the additional xing of items such as carpet grip rod or door threshold strips may be tted at a future date.

Polypipe does not recommend the application of two layers of timber oor covering as this will severely reduce the heat output of the under oor heating system.

Correct application

Incorrect application

If a manufactured timber oor is to be used then it is recommended that this be of a suitable load bearing quality. (Please request advice from the specialist ooring supplier).

Battern systems

Used for spans greater than 450mm or less than 350mm.

Where it is not possible or desirable to drill or notch the oor joists,

and the oor height can be raised, spreader plates can be used.

Fitting insulation with a battern system

Step 1:

To prevent downward heat transmission, insulate between the

voids in the joists with appropriate foam insulation.

Fitting the batterns

Step 2:

Lay 75mm x 25mm battens across the existing joists at 450mm centres.

Trim the ends of the batten back to the last joist at alternative ends.

Fitting the spreader plates

Step 3:

Lay spreader plates between the battens and pin in position.

Laying the pipe

Step 4:

Lay pipe into the spreader plates in accordance with the installation

instructions on the previous page, ensuring you follow the

testing procedure.

Joists at spacing

greater than

450mm or less

than 350mm

Polyplumb

barrier pipe

Pipe clip

75mm x 25mm

battens at

450mm centres

Polyplumb

barrier pipe

Double heat

spreader plate

Joists at spacing

greater than 450mm

or less than 350mm

25mm thick dry mix screed Insulation

Tongue and groove ﬂooring Joists

MODULAR HEATING PANEL

22 23

Maximising heat efﬁciency

Product options

A new concept

in under ﬂoor heating

Modular Heating Panels* are an exciting new product concept from Polypipe that enable quick and simple installation of under ﬂoor heating into suspended ﬂoors in both new build and renovation projects.

Installing under oor heating into upper oors can be challenging, even in new build projects. Most conventional under oor heating systems comprise a single section of pipe, housed or placed within another part of the system structure, such as oor panels, which are cut to size on site. This works ne as there are no interruptions to the laying of the pipe. In suspended oor installations however, the pipe, plates and insulation have to t within an obvious obstruction: the supporting oor joists. It is working around the joists, and avoiding other services, that has often led to under oor heating being avoided in upper oors.

As the name suggests, a Modular Heating Panel (MHP) is a pre-congured solution, where all of the oor heating system components are supplied tted within complete panels, which are simply tted and connected together on site. Thanks to MHP it is now possible to t panels quickly into the existing joist voids and connect them to a standard heat source.

MHP works with both traditional and engineered joists and can be tted from above or below.

Due to their high output at relatively low ow temperatures, Modular Heating Panels are ideal for maximising heat efciency and lowering energy consumption. In most installations it is not necessary to cover the entire oor area. MHP panels work like “under oor radiators”, applying enough heat to only those areas of the oor that need to be heated and using just enough of them to maintain a suitable room temperature.

For a room temperature of 20°C, for example, only 80% oor coverage is required to provide 70W/m

or around 60% for 50W/m2.

This unique product benet also makes MHP an ideal solution when using heat pumps.

The exibility of panel placement provided by MHP means that oor areas to be covered by items such as built-in wardrobes or baths and shower cubicles can be avoided without detriment to the overall heating provision.

MHP is available in 4 panel sizes comprising 2 lengths and 2 widths:

MHP available lengths: 1.3m and 2.0m

MHP available widths: 380mm and 490mm

Each MHP panel contains pre-installed pipe circuitry, 30mm

of insulation, and is covered in heat diffusing foil. Pipe circuitry

is based on 10mm diameter pipe. A 500mm length of pipe

extends from each panel allowing connection to the ow and

return pipe work from an under oor heating manifold.

MHP panels are easily installed from either above or below

and suit the joist widths of both composite ‘I’ beam joists and

traditional timber joists. Up to 3 MHP panels can be connected

together in series and the recommended maximum room area

per circuit is 20m

Heat diffusion foil 30mm insulation 10mm pipe circuit

*Patent pending.

Designing your layout

Designing the ideal room layout for an MHP installation and

selecting the required products couldn’t be simpler.

Follow the steps below or use the online product selector tool

at www.ufch.com/mhp

Select panel width

Step 1:

The spacing of joists and the available gap will determine which

MHP panel width will be most suitable for each project. Select the

MHP width nearest to the gap width, ensuring that this does not

encroach on the space for other services.

The 490mm width panel will normally be tted in the wider joist

spacing used by composite joists and ‘I’ beams.

Select panel length

Step 2:

The span of the joists in each room will determine which MHP panel

length should be selected. The span is dened as the free space

from wall to wall that needs to remain uninterrupted by trimmers

or other services. Ideally, install MHP panels prior to other services

whenever possible.

Use the table below as a quick guide to suitable arrangements

of MHP panels leaving a 200mm gap for pipe connections.

24 25

Planning your room arrangement

Step 3:

Calculating the amount of oor area to be covered by MHP will be

based on the required heat output (see our heat output tables on

page 27) and will take into account areas of the oor that do not

require heating, such as under built-in wardrobes, baths and

shower cubicles.

The diagram below illustrates a typical layout that

might be considered.

1 x 1.3m Panel

SpanArrangement

1 x 2.0m Panel

2 x 1.3m Panels

1 x 1.3m Panel + 1 x 2.0m Panel

2 x 2.0m Panels

1.4m to 2.2m

2.2m to 2.8m

2.8m to 3.5m

3.5m to 4.2m

4.2m to 5.0m

26 27

Panel layoutsPre-installation requirements

Planning

Before installing MHP panels ensure you have planned out the

positioning of the required panels avoiding all other services such

as electrics, gas and water supply.

You will not need to do any specic preparation for the

installation in a new build property as there will be no ceilings

or oors in place.

For existing room refurbishment, you will need to take up your

oor if tting from above or take down the ceiling if tting from

below. Ensure that the area where the MHP panels are to be

positioned is free from any debris before commencing installation.

Installation

Installation from above

To install MHP panels from above simply t support bearers to

each side of the joists. These support bearers should be positioned

30mm from the top of the joist and the MHP panel is then simply

laid on to these supports.

Installation from below

When installing MHP panels from below you will need to mark

out the positioning of the panels to ensure you have them

situated in the correct places for heating the room above.

Once you have checked the marked out positioning, the MHP

panels can be slotted into place and xed to the underside

of the oor using 1¾” x 8 woodscrews with M6 x 30 dia washers.

It is advisable to use 6 xings per panel ensuring you avoid the

moulded pipe marking on the underside of the panel and x

each panel securely.

IMPORTANT NOTE: Polystyrene can cause deterioration to cable

insulation when it comes into direct contact with it.

Always ensure that electrical cables are not in physical contact

with the MHP panels using tape or a polythene strip.

Finishing

Once you have connected your system up to the manifold and

tested it you can then nish the room by tting the oor or ceiling

in the normal way depending on whether you have installed MHP

from above or below.

Testing

Where possible installations should be tested at 20°C to

18 bar pressure. Any installations once connected to the manifold

have a maximum test pressure of 6 bar.

Product Information

Product Code No of panels per pack

MHP 490mm (W) x 2.0m (L) MHP49020 5

MHP 490mm (W) x 1.3m (L) MHP49013 5

MHP 380mm (W) x 2.0m (L) MHP38020 5

MHP 380mm (W) x 1.3m (L) MHP38013 5

Heat Output

Maximum oor area for ow and return 20m

Room at 20°C Heat output per panel

Flow Av. ﬂoor MHP49020 MHP49013 MHP38020 MHGP38013 temp (°C) temp (°C) (W) (W) (W) (W)

40 25.0 63 42 49 33

45 25.8 75 50 58 39

50 26.6 86 58 67 45

55 28.9 120 80 93 62

60 30.8 147 99 114 77

Approximate coverage required:

For 70W/m2 room = 80% coverage

For 50W/m

room = 60% coverage

Connect up to 3 panels in series

Maximum coverage per circuit 20m

1 panel layout

15mm Polypipe ﬂow and return

connections to manifold

15mm Polypipe ﬂow and return

connections to manifold

Part No: PB010 10mm Straight Coupling

Part No: PB1115 15mm - 10mm Reduced Branch Tee

Part No: PB015 15mm Straight Coupling + Part No: PB1815 15mm - 10mm Socket Reducer

Part No: PB1115 15mm - 10mm Reduced Branch Tee + Part No: PB1815 15mm - 10mm

Socket Reducer Part No: PB1115 15mm - 10mm Reduced Branch Tee + Part No: PB1215 15mm - 10mm Reduced Branch Spigot Tee

2 panel layout

1 2 3

OVERLAY

28 29

OverlayTM is a unique low proﬁle ﬂoor heating system ideal for both renovation and new build projects.

Installed over the existing oor and only 18mm in depth, Overlay™ allows oor heating to be installed where traditional under oor systems would either require expensive excavation or would require the oor to be raised to an unacceptable level.

The Overlay™ system is available in 2 panel types to allow for installation to all build types and oor coverings.

Overlay™ panel is a brous panel used for heavyweight oor coverings such as ceramics, or where the oor covering needs to be secured directly to the panel, e.g. solid wood.

Overlay™ Lite is a high compressive strength, lightweight insulated panel used for lightweight oor coverings, e.g. laminate, engineered wood and carpet. Due to its ease of handling and cutting it is also more suitable for larger areas and multiple room installations.

Overlay™ systems use a 12mm pipe at 150mm pipe centres and provide excellent response times and heat output compared with traditional built in under oor heating solutions and are therefore ideal for both traditional heating systems and low temperature renewable systems.

Under ﬂoor heating that ﬁts over existing ﬂoors

Key design and installation information

Material requirements (approx)

Maximum heat output Approx. 100W/m

Recommended design ow temp 45° to 50°C

Maximum circuit length 80m

Maximum coverage per circuit 12m

Overlay™ oor panel Coverage 0.48m

Overlay™ Lite oor panel Coverage 0.75m

Pipe 7m length/m

End returns 1 return bend per oor panel

12mm x 80m coil of pipe 1 coil per circuit

15mm x 12mm adaptors & stiffeners 1 pack per circuit

30 31

Choosing your Overlay™ panel

Overlay™ accommodates all types of project and oor coverings and the only choice is that of which panel will be most appropriate for the installation. Both Overlay™ and Overlay™ Lite can be used for the majority of projects, however as Overlay™ Lite is the quickest and easiest system to install, this should be the rst consideration for most projects.

The more structural nature of Overlay™ however makes it ideal for direct tiling or application of oor nishes which need to be xed or screwed to the panel.

6mm plywood lining

600mm x 1244mm Overlay™ Lite panel

Heat diffusion foil

End return Suitable for:

Laminate Vinyl Carpet

12mm pipe circuit

18mm ﬂoor panel

Fits over concrete or ﬂoorboards

OverlayTM Lite

for lightweight ﬂoor coverings

Overlay

for heavyweight ﬂoor coverings

Suitable for: Tile Hard wood

600mm x 800mm Overlay™ panel

End return

12mm pipe circuit

18mm ﬂoor panel

Fits over concrete or ﬂoorboards

Project type

Overlay™ Overlay™ Lite

Single room / small areas Yes Yes

Multiple room / large area With careful Yes planning

Overlay™ Overlay™ Lite

Tiles / slate / other ceramics Direct With plywood overboard

Natural wood Direct & xed No

Laminate Yes Yes & engineered laminate

Carpet & vinyl With plywood With plywood overboard overboard

Floor covering

32 33

Pre-installation requirements

Planning

Planning the Overlay™ system beforehand will save time during

installation and minimise product waste.

The direction the pipe runs to and from the ZRU or manifold and

use of the return bends will be the main considerations.

The end returns have a at panel which forms a channel to allow

the routing of pipes to multiple circuits in the room. This can be

removed where necessary.

Floor areas which don’t require pipe circuitry, e.g. beneath kitchen

cupboards or sanitary ware, can be ‘blanked’ using 18mm plywood

or chipboard. This will make better use of the Overlay™ products.

This can also be used to ‘square off’ rooms with irregular walls.

Example of ‘blanking’ on kitchen plan

Example of ‘blanking’ in a bathroom

Example of ‘squaring off’ an irregular room plan

Room layouts

The following diagrams show some examples of room shapes,

pipe requirements and interruptions (pillars, hearths, etc.)

which need to be accommodated.

Room with 2 circuits

Room with pillars/hearth

Pipe layouts in multiple room installations

Multiple room installations require several circuits and careful

planning is required close to the manifold to allow for all pipes

to be accommodated.

Wherever possible pipes can simply go through, rather than

round, walls to eliminate the number of pipes requiring access

through the entrance of the manifold cupboard.

Alternatively leave voids at the edge of the panels.

Using return bends as routers or using supply pipes

to heat corridors are all ways of managing the installation

in this area.

3 4

End Return with panel removed

End Return

End Return with panel removed

End Return

Step 3:

When you get close to end of the rst row t two end returns against the wall as in step 1 and if necessary cut an Overlay™ panel to t and complete the rst row.

Cutting the panels

Panels can be cut using a hand saw or jigsaw set at a low speed.

(Cutting these panels will generate dust so should either be done

outside or in a ventilated room. Ensure you wear a particle mask.)

Step 4:

Once you have completed the rst row begin the process again, gluing the ends and sides of each panel, staggering the panels in the second row in a brickwork pattern and continue until the room is complete.

Laying the pipe

Step 5:

Starting from your manifold position and allowing enough pipe for connections lay the pipe into the grooves of the Overlay™ panel in accordance with your plan.

Finishing

Using a oor ller/grout ll any gaps and voids, and ll around any pipework.

Tiles can be laid directly on to the Overlay™ panels or a 6mm plywood lining can be tted prior to tiling.

When tiling directly over Overlay™ panels, use a sealant with exible adhesive and grout.

If tting solid wood oors they can be discretely screwed through the tongue and groove directly into the Overlay™ panel, avoiding pipe circuitry, to minimise movement in the oor covering.

If over-boarding with 6mm plywood, this can be glued, stapled or screwed to the Overlay™ panel, avoiding the pipe circuitry.

Plywood cover where required

34 35

Overlay™

for heavyweight oor coverings

Installation

Laying end returns

Step 1:

Start by xing two end returns to the oor in a corner of the room.

(Remove the pipe panel if not required as per your oor plan).

This should be done by using suitable screws in the screw holes

of the end return panels when xing to a wood oor, or by using

Overlay™ adhesive (code PB777) to bond the end returns

to solid oors.

Laying the panels

Step 2:

Clean down the edges of the panel and apply a 3mm bead of adhesive to the top edge. Then lay it, ensuring you line up the grooves in the panel with those in the end returns. Continue to lay the rst row of panels gluing each joint to achieve a secure installation.

When gluing the ends, ensure there is no residual glue in the pipe grooves and use short lengths of pipe to help with panel alignment.

First panel

Room wall

Return bends with pipe plate remaining

Return bends with pipe

plate removed

First row Subsequent row

Step 4:

Once you have completed the rst row begin the process again with

the second row, staggering the panels in a brickwork pattern.

Step 5:

Use the self adhesive foil tape along the long panel joints to securely

x the panels to the adjacent row.

Step 6:

Now continue this process, completing the whole room.

Laying the pipe

Step 7:

Starting from your manifold position and, allowing enough pipe for

connections, lay the pipe into the grooves of the Overlay™ Lite panel

in accordance with your plan.

Step 8:

Once you have nished laying the pipe use the self adhesive foil tape

to secure the panels and pipe, running across all the panel joints, and

do the same across the joints where the panels meet the end returns.

Finishing

Laminate and engineered wood can be laid directly over Overlay™

Lite panels. Where carpet or vinyl is being tted, rst x a 6mm layer

of plywood using a contact adhesive, then continue to lay the oor

covering as normal. It is advisable to mark out pipe positioning

to avoid stapling pipes when tting carpets.

36 37

Overlay™ Lite

for lightweight oor coverings

Installation

Laying end returns

Step 1:

Start by xing two end returns to the oor in a corner of the room.

(Remove the pipe panel if not required as per your oor plan).

This should be done by using suitable screws in the screw holes

of the end return panels when xing to a wood oor or by using

Overlay™ adhesive (code PB777) to bond the end returns to

solid oors.

Laying the panels

Step 2:

Lay the panel ensuring you line up the grooves in the panel with

those in the end returns then continue to lay the rst row of panels

using short lengths of pipe to help with panel alignment.

Step 3:

When you get close to end of the rst row t two end returns

against the wall as in step 1 and if necessary cut an Overlay™

Lite panel to t and complete the rst row.

Cutting the panels

Panels can be cut using a sharp knife and a metal rule.

First panel

Room wall

Return bends with pipe plate remaining

Return bends with pipe

plate removed

First row Subsequent row

38 39

MANIFOLDS

Manifolds are common to all systems above 30m2, independent of the under ﬂoor heating system. Manifolds are supplied complete and ﬁxed to the wall mounting bracket.

The manifold comes complete with a drain and air vent assembly, which can be positioned on either end of the manifold. Isolation valves are supplied separately for the supply end of each manifold.

The bottom manifold is the ow and the top manifold is the return. Each manifold port comes complete with a Polyplumb push t connection. Pipes are connected to manifolds by inserting a pipe stiffener into the pipe and simply push tting the pipe into the port.

The ow meter on each ow port of the manifold provides a visual indication of the ow through each circuit.

Both manual and lockshield balancing can be undertaken by either using the blue cap on the return manifold for manual adjustment, or removing the blue cap and adjusting using the key supplied with each manifold.

Preparing and installing the manifold

Remove the manifold from the box and arrange the ow and return manifolds to ensure that the inlets/outlets are pointing downwards. Remove the air vent and drain valve from the packaging and connect to the desired end of the manifold.

Ensure the seal is correctly in place before tightening the compression nut by hand on to the manifold. To ensure the valves are securely connected to the manifold, use a 38mm spanner or wrench to tighten by a further half turn.

Remove the isolating valves (supplied separately) from the packaging and connect to the opposite end of the manifold. As with the air vent and drain valve, ensure the seal is correctly in place before tightening the compression nut by hand on to the manifold. Then, complete the connection by using a 38mm spanner or wrench to tighten by a further half turn.

Fix the manifold horizontally in the desired position utilising both screw holes on each bracket.

The manifold is now in position and ready to be connected to the mains from the boiler and the under oor heating pipe circuits. A set of self adhesive stickers are included to help identify each circuit on the manifold. The stickers also provide the opportunity to record the number of turns required for the correct ow rate through each circuit (for further information on testing and commissioning see pages 46 and 47).

80 50

Outlets 2 3 4 5 6 7 8

L (mm) 190 245 300 355 410 465 520

Outlets 9 10 11 12 13 14

L (mm) 575 630 685 740 795 850

Dimension

1”

A (mm) 39 B (mm) 64 C (mm) 86

CONNECTING TO HEAT SOURCE

Polypipe under ﬂoor heating systems are designed to be connected to a variety of heat source options.

Gas and oil boilers

When connecting to any heat source it is essential that the under oor heating manifold(s) are fed directly from the heat source with a dedicated set of ow and return primaries, to enable total independent hydraulic control of the under oor heating system. Under no circumstances should this primary feed be connected into any other heating pipework, such as radiator or domestic hot water primary circuits.

To provide independent hydraulic control of the entire system, it is important that the installation is designed as an ‘S Plan’ or ‘S Plan Plus’ conguration which allows for a two port zone valve to be tted to all primary circuits and at each under oor heating manifold (see diagram).

IMPORTANT NOTE: Under no circumstances should a Polypipe under oor heating system be connected in to a ‘Y Plan’ (ow share) system as this will result in serious system operating problems.

To ensure that the correct operating temperatures and system ow rates are maintained for the under oor heating system, the manifold(s) should be tted with a manual blending valve and circulating pump (see section ‘Water temperature controls’). However, it is the responsibility of the designer/installer to ensure that the boiler and system pump are capable of providing sufcient outputs in order to meet the requirements of the primary pipework, the under oor heating system and any other equipment installed in the system.

Typical ‘S Plan Plus’ conﬁguration

Typical ‘S Plan Plus’ conﬁguration via thermal store

Heat pumps

Polypipe under oor heating systems are ideal for use with heat pump systems due to the lower operating temperatures that are produced by this type of heat source. However, to provide temperature limitation protection and sufcient system ow rate for the under oor heating installation, it is recommended to t the manual blending valve and pump pack as supplied by Polypipe Building Products Ltd.

It is the responsibility of the system design/installer to ensure that the heating circulation pump supplied with the heat pump, and any associated primary pipework, is capable of providing sufcient duty to meet the demand up to the under oor heating manifold assembly. This also applies if a ‘buffer tank’ has been tted to the heat pump installation.

A buffer tank or thermal store is often tted between the heat pump and the under oor heating system. This is to provide a sufcient quantity of stored water to feed the under oor heating system and to ensure that the heat pump ow rates are maintained, thereby reducing the risk of cycling. By using a buffer tank installation there is no need to use ‘open circuits’ at the under oor heating manifold, therefore allowing individual room control.

The Underoor Heating Manufacturers Association (UHMA) do not recommended that the under oor heating system be used as an ‘open circuit’, to provide the ow rate requirement for the heat pump installation, as this could lead to problems with system control at a later date. For further information regarding the installation of the system please contact the Polypipe Technical Hotline on 01709 770000.

Solid fuel and wood burners

Under no circumstances should a Polypipe under oor heating system be connected directly to this type of heat source. Instead, the burner should be used to provide indirect heat via a thermal store or similar neutraliser. The low temperature feed from this store can then be pumped to the under oor heating manifold, as with a heat pump installation.

Please seek specialist advice from the heat source supplier or manufacturer before commencing the installation.

40 41

ROOM TEMPERATURE CONTROL

Controlling under ﬂoor heating

The control of under oor heating systems is different to that of conventional radiator systems, as the space should not be allowed to cool completely during the heating season. The temperature during unoccupied or night time periods should fall to around 4°C lower than the occupied temperature.

This lower temperature setting is known as the set-back temperature, e.g. occupied temperature 21°C, set-back temperature 17°C.

Individual room control

Polypipe under oor heating controls allow each room to be both time and temperature controlled via the use of a programmable room thermostat. Each thermostat is wired back to a master wiring centre and slave unit, which in turns operates the relevant manifold actuator/s, the under oor heating pump, and the two-port zone valve. The master wiring centre is also capable of providing either a 230V or a Volt free switched live supply to signal the boiler.

Schematic switching diagram - relays not shown

As individual rooms reach their set point temperature or when the system is operating in ‘set back’ mode the master wiring centre will de-energise the pump and zone valve and the signal to the boiler will be cut, ensuring that maximum comfort levels and system efciencies are achieved and maintained at all times.

The number of control zones you require will depend on the number of rooms you wish to control individually. The 4, 6 and 8 zone packs describe the number of areas you wish to control, not necessarily the number of circuits you are supplying from that manifold. To optimise the use of each control pack you will need to understand the following guidelines:

• The 4 zone pack contains 4 room thermostats; the 6 zone pack contains 6 room thermostats; and the 8 zone pack contains 8 room thermostats

• Each room thermostat can control 1 zone and up to 4 actuators

• Rooms over 40m

should be allocated as 2 zones

and have 2 room thermostats

• An actuator is required on each circuit that requires control

The room thermostats (PBPRP) and wiring centres are available as individual items or packs, as detailed below:

A comprehensive range of room temperature control products are available to complement Polypipe under ﬂoor heating systems. Designed speciﬁcally to maximise both comfort and efﬁciency, the unique programming functions provide the perfect control solution for under ﬂoor heating systems.

WATER TEMPERATURE CONTROLS

The temperature of water required in under ﬂoor heating systems is less than that required for radiators or stored hot water. If these other services are connected to the same boiler it will be necessary to control the water temperature using one of the Polypipe water temperature control units.

All Polypipe under oor heating system packs supplied through the selection process will contain all the appropriate control products.

Modulating pump unit (PB970014)

The modulating pump unit controls water temperatures between 45°C and 60°C. The inclusion of a modulating pump ensures that the ow to the under oor heating circuits is automatically adjusted to allow for the opening and closing of actuators when individual room temperature is required. The unit is suitable for manifolds demanding up to 15kW heat load.

The temperature of the water is set using the pilot pin on the hand wheel. When the pilot pin is ush with the hand wheel the temperature is set to 55°C. Each click to + or – increases or decreases the temperature by 1°C.

The modulating pump unit is tted directly to the manifold at either end by turning the pump through 180°. An additional zone valve is required when using a modulating pump unit supplied by other manufacturers.

Floor heating control pack (PB970015)

The pack controls water temperatures between 35°C and 60°C, and incorporates a xed head pump and a 22mm 2-port zone valve, which is suitable for manifolds demanding up to 15kW heat load. The set temperature of the water is shown on the wheel head.

The control pack is tted directly to the manifold at either end, as both left hand and right hand connector bends are supplied with the unit.

Dimensions of assembled unit

NOTE: The valves shown on this diagram are purchased

separately and not supplied with the unit.

Manifold bends (PB12735)

The water temperature control packs can be tted at 90° to the manifold using the manifold bends. This allows manifolds and pump units to be corner mounted where space is at a premium, e.g. in an understairs cupboard.

A) Manifold bend installed with modulating pump unit B) Manifold bend installed with oor heating control pack

A) B)

290mm

Pilot pin ﬂush to handwheel

260mm

155mm

110mm

50mm

30mm

130mm

40mm

Product Class Rating IP Rating

PBPRP Class 2 IP30

PBPRP RF Class 2 IP30

PBTSP Class 2 IP20

Electrical protection index

Actuator

room 2 closed

Actuator

room 1

open

Room

thermostat

room 2 satisﬁed

Room

thermostat

room 1

demand

Zone

valve open

Circuit

room 1 open

Circuit

room 2 closed

Boiler

UFH Pump

Pack Single Zone 4 Zone 6 Zone 8 Zone

PB1ZP PB4ZP PB6ZP PB8ZP

1 Zone Master 1 1 1 1

4 Zone Slave 1 2

6 Zone Slave 1

Programmable Room Thermostat 1 4 6 8

Pack

Code

Content

42 43

Programmable room thermostats

Programmable Room Thermostat PBPRP:

The PBPRP remote programmable room thermostat is a battery

operated unit and offers the following outstanding features:

• 24 hour / 7 day time and temperature control

• Optimised system start

• Set-back temperature setting

• Frost protection facility

• Holiday standby function

• Five pre-set programmes for ease of set up

• Battery low indicator

• Standard battery replacement 3 x AA LR06 1.5v (two year life)

• No loss of memory when battery change is carried out

• Wet room sensor connection provided

Wet Room Sensor PB23020:

Where time and temperature control needs to be applied to

a bathroom or wet area, the wet area sensor can be installed

within the wet room and connected to the programmable room

thermostat installed in an adjacent dry area.

The sensor is supplied with 3m of cable and can either remain in

the supplied housing and be wall mounted, or removed from the

housing and used as a oor surface sensor.

If required, the wet room sensor cable can be extended to

a maximum of 10m providing that a cable of a similar rating

is used (NTC 10k).

All Polypipe under oor heating system packs supplied through the selection process will contain all the appropriate control products.

Programmable Room Thermostat PBPRPRF (radio frequency):

As PBPRP unit but with the following additional features:

• Full RF operation

• Each programmer supplied with a receiver unit

• Remote thermostat has built in stand for ease of positioning

• Blue LED backlight

Touch Screen Programmable Room Thermostat PBTSP:

The PBTSP incorporates the latest touch screen technology and

is fully compatible with the master wiring centre and slave units.

Available in two surface nishes, and offers the following features:

• Large touch screen display with high visibility blue LED backlight

• On screen display shows current status and programme setting

• Programme options for 7 day, 5+2 days and working

week/weekend modes

• Allows for three separate temperatures settings per day;

- Comfort

- Economy

- Night

• Holiday standby function

• Frost protection

• Battery operated using 2 x AA LR06 1.5V (two year life)

• Available in either white (PBTSPW) or silver (PBTSPS)

Please note that the PBTSP is not compatible with the Polypipe

wet room sensor (PB23020).

Wiring centres

Single zone master (PB1ZM):

When used in a ‘single zone’ application the master wiring centre (PB1ZM) provides the wiring connections for the under oor heating pump, two-port zone valve, boiler switched live connection (230V or volt free) and the programmable room thermostat.

Wiring details for single zone master unit (PB1ZM)

4 & 6 zone slave unit (PB4ZS & PB6ZS):

Where multiple room control is required the master wiring centre should be used in conjunction with the 4 or 6 zone slave units PB4ZS or PB6ZS. The slave units provide wiring connections for the programmable room thermostats and the manifold 2-wire actuators. Up to 4 actuators can be connected per zone.

Wiring details for 4 zone and 6 zone slave (PB4ZS and PB6ZS)

Note: Only use this connection when using a Single Room Thermostat. If using Slave do NOT use.

230v

Supply

OR OR

Polypipe Room Stat Options

Remove Link if Zone Valve Fitted

Power Supply UFH Pump

2 Port Zone Valve

Volt Free

Contact

Boiler

230v S/L

Connection

Boiler

COM

LNE ENL

End Switch

LNE

LNC

C1LN

230v

Supply

OR OR

Polypipe Room Stat Options

C1LN

COM

Up to 4 Actuators per zone

2 Wire Actuators PB00401

Note: 1 Zone shown only Repeat for further Zones Must be used with Master Unit

44 45

SINGLE ROOM APPLICATIONS

All Polypipe under oor heating systems can be installed in single rooms and connected to the existing wet heating system. In rooms greater than 30m

it is recommended that the connection to the under oor heating system is made via a manifold and installed in the same way as a multiple room installation with single area control.

Areas of up to 30m

should use the Polypipe Zonal Regulation unit (ZRU) as this provides a simpler method of connecting into the existing system, without the need for expensive hydraulic or electrical alterations.

The ZRU simply connects to the existing heating system providing:

• Water temperature control (30°C to 60°C) for the under oor heating

• The correct ow rate the under oor heating

• Automatically switches On and Off via a built-in pipe thermostat

• A wiring connection for a room thermostat or wireless sensor

• Can be connected to operate the under oor heated room independently with the existing system

Connections to the existing wet heating system

The pipe work connections to the ZRU are for 15mm diameter pipe and the ZRU should not be connected to the system from any pipe smaller than 15mm.

A small number of boilers can be affected hydraulically by the use of a second pump in the system.

NOTE: Check with the boiler manufacturer to ensure compatibility with the ZRU.

The preferred connection to the ZRU is to the main ow and return pipe work of a 2 pipe system, i.e typically from 22mm distribution pipe work. However it can also be connected to the nearest existing radiator.

Pipe connection to operate under ﬂoor heating at the same time as the boiler

The diagram above shows the ZRU connected to operate with the boiler on/off ring. Due to the quick response of low mass systems (Overlay™, Overlay™ Lite, MHP, etc) this is likely to be suitable. Using this method for solid oor installations may require the timings of the existing heating to be altered to allow the under oor heating system to reach comfort temperature.

If the room is to be controlled independently of the existing central heating system, a zone valve needs to be installed between the boiler and the ZRU.

Pipe connection to operate ZRU / under ﬂoor heating independently

Programmable room thermostat

Connection from main distribution pipe work

Zone valve to under ﬂoor heating

Zone valve to radiator, etc

Connection from main distribution pipe work

Connection from nearest radiator

260mm

200mm

Pump

Pipe thermostat

Heating return

Heating ﬂow

Under ﬂoor heating ﬂow

Under ﬂoor heating return

Thermostatic blending valve

Pump speed control

Tees and spigot elbows for second circuit if required

Room stat (example) - not supplied

Pump

Remove

link if

using a

room

thermostat

Boiler feed thermostat

42°C close 31°C open

Mains

(Fused spur)

3amp

The pipe supplying the ZRU should be connected to the main boiler distribution pipe prior to the connection of other zone valves.

A programmable room thermostat can be used to operate the zone valve and, in turn, the end switch within the zone valve can provide a signal to re the boiler.

Installation of ZRU

The ZRU can be positioned either in the room where the under oor heating is installed or in an adjacent area, 300mm from the nished oor level to allow for pipe connections.

Fitting the ZRU

Step 1:

Screw unit to wall.

Connecting the ZRU

Step 2:

Connect heating pipe work via an isolation valve (as shown).

Step 3:

Connect under oor heating circuit(s) using an isolation valve. Use tees and spigot elbows to form connections for 2 and 3 circuit systems.

Step 4:

Connect mains wiring (as diagram below) via a fused spur.

Wiring details

IMPORTANT NOTE: If in any doubt you should contact

a qualied electrician.

The water temperature must be 45°C to operate the unit.

Wiring diagram

Filling the under ﬂoor heating system

Use the heating system to ll the under oor heating circuits and ZRU.

Blanking off the ZRU

Step 1:

Remove the under oor heating return pipe from ZRU and blank off the ZRU under oor heating return port with a short pipe with a blank end or a blanking plug.

Filling the ZRU

Step 2:

Allow open ended under oor heating return pipe to drain into a bucket or hose.

Step 3:

Open the ow isolation valve to the ZRU.

Step 4:

When uninterrupted ow is seen from the under oor heating return pipe, close the isolation valve and re-connect the under oor heating return pipe to the ZRU.

Step 5:

Open all the valves.

Step 6:

Vent the ZRU through the air vent and pump vent.

Room packs

Open under ﬂoor heating ﬂow isolation valve

Blank off under ﬂoor heating return to ZRU

Vent under ﬂoor heating system from under ﬂoor heating return pipe

Type Solid Floor Overlay™ Overlay™ Lite

Area 12m2 (So12Z) 12m2 (O12Z) 12m2 (OL12Z)

20m2 (So20Z) 20m2 (O20Z) 20m2 (OL20Z)

30m2 (So30Z) 30m2 (O30Z) 30m2 (OL30Z)

A 5m2 Overlay™ Bathroom Pack (O5B) is controlled with a temperature limiting valve rather than the ZRU

A range of room packs containing all ﬂooring and ZRU are available

46 47

Slowly open the valve by turning the spindle anti-clockwise until the required ow rate in l/min is achieved in the ow meter window.

When adjusting the manifold ow rates care should be taken to ensure that the adjustment spindle is not left with any of the thread showing.

In order to carry out any maintenance to the installation it is possible to isolate individual circuits by closing both the ow and return ports, as shown in the diagram below.

NOTE: The isolating valve tted to the manifold ow meter is not used for balancing purposes.

If it becomes necessary to close off a manifold completely, this can be done by using a ¾” brass cap with a suitable rubber washer insert.

Once all of the circuit ow rates have been adjusted the system should be left to operate for a short period whilst any remaining air is removed. Once this has been done the ow rates should be re-checked and adjusted if necessary before the actuator heads are tted. If the actuator heads are not likely to be tted for a while then it is recommended that the blue caps are used in order to protect the ow rate settings and prevent any debris from entering the ow valve assembly.

IMPORTANT NOTE: When using the PB970014 Modulating Pump Unit to ensure that the primary boiler ow temperature provided at the manifold is at least 15°C hotter than the required manifold operating temperature. This is due to the fact that this manifold uses an ‘injector method’ to mix down the primary water. Furthermore, when balancing the system with this particular manifold kit please ensure that the modulating pump is set to a xed head speed whilst making any adjustments.

SYSTEM COMMISSIONING

Initial system ﬁlling

Close the manifold isolating valves (1) & (2). Connect a hose pipe to the manifold return drain off point (4) and take to a drain. Connect a second hose to the manifold lling point (3) and attach to a mains cold water supply (3 bar max). The connections to the manifold drain and ll points are ¾” BSP. Use exible ¾” tap connectors for the simplest method of connection.

Close all under oor heating circuits except one, by screwing down the blue caps and closing the isolating valves situated on top of the manifold ow meter. Flush the rst circuit with mains cold water until all of the air has been purged. Once this has been done close the rst circuit and repeat the process for all of the other circuits on the manifold.

Once the system has been lled and purged of air, and before any screed is laid, a system pressure test must be carried out to conrm the integrity of the installation. It is recommended that this test be done using a suitable hydraulic pressure test kit and not with air.

NOTE: The system pressure test should be carried out with the manifold pump pack removed.

Close the manifold isolating valves and connect the pressure test pump to the manifold ow rail using the ¾” threaded connection on the lling/drain-off point (3). Pressurise the system to 6 bar max and leave under pressure for 1 hour.

Once the pressure test is complete reduce the system pressure down to 3 bar to protect the pipework whilst any screeding process is carried out.

IMPORTANT NOTE: Do not leave the system under pressure during periods of extreme cold weather or when there is a risk of freezing.

System balancing

Once the system is up and running it is necessary to balance the system in accordance with the design data provided. This should be done using the following method:

Ensure that the boiler and main system duty pump are operating correctly and that sufcient heat input and ow rates are being provided at the manifold(s).

Set the under oor heating controls to call for heat and check to see that the two-port zone valve and manifold pump are energised.

Remove the blue cap from the manifold ow port and, using the bleed key provided, turn the ow adjustment spindle clockwise to completely close the circuit.

Once installed, Polypipe under ﬂoor heating systems should be tested thoroughly to ensure they are working effectively, including initial ﬁlling of the system and system balancing. If you require any further information please contact the Polypipe Technical Team on 01709 770000.

Heat output tables

The tables below shows typical performance data for the various Polypipe under oor heating systems.

Solid Floor

Suspended and Floating Floor

Overlay™ and Overlay™ Lite

MHP System

48 49

General system information

Many of the components within Polypipe under oor heating systems are drawn from our well established Polyplumb system of pipes and plumbing ttings. Polyplumb is suitable for use in hot and cold water supply and both radiator and under oor heating systems. Polypipe polybutylene pipe provides exibility and freedom when designing pipe layouts, whilst Polyplumb push t ttings are fast to install and secure in use.

Strength

The Polyplumb system is suitable for use in working applications up to 12 bar / 20°C (6 bar / 90°C). Pipes are suitable for bending to a radius of 12 x diameter when unsupported or 8 x diameter when supported. Connections and ttings are tested to BS 7291: Class S for thermal cycling test, long term pressure tests, rapid pressure test and pull-out strength.

System malfunction temperature

Polyplumb pipes and ttings are tested to BS 7291: Parts 1 and 2, which incorporates a pressurised thermal cycling test and a test regime at temperatures of 114°C and 3.5 bar pressure for 1,000 cycles at a duration of 30 minutes per cycle. See British Standards website for further details.

Gases

The Polyplumb pipe system is not suitable for the transportation of gases. Standard Polypipe polybutylene pipe is oxygen permeable and is only suitable for all domestic water and heating installations. Polypipe recommends that corrosion inhibitors are introduced to, and maintained in, all heating systems, whether they use standard or barrier pipe. Due to the long pipe runs used in under oor heating systems, we recommend barrier pipe is used throughout to minimise the potential for oxygen ingress into the system.

Light

Polyplumb pipe and ttings should be protected from UV light. Standard decorating paints form adequate protection. Polyplumb pipe insulation forms adequate protection for external use. All Polypipe polybutylene pipe is delivered in light-protective packaging.

Thermal

The co-efcient of thermal expansion of Polypipe polybutylene pipe is 1.3 x 10

-4

m/mºC. It accommodates expansion by its

modulus of elasticity.

Maintenance

Polypipe systems require no maintenance, other than checks on the inhibitor level in heating systems.

Water

The polybutylene material used in Polyplumb pipes and ttings is WRC / WRAS approved. It is resistant to the build-up of scale. Short term chlorination for disinfection of supply pipe work and normal levels of chlorine in UK domestic water supplies will not have an adverse effect on the integrity of the pipe. Polypipe pipe is not suitable, however, for systems that carry a high concentration of chlorine, for example supplies to swimming pools.

Acoustic

The exibility of Polypipe polybutylene pipe provides better acoustic performance than rigid pipe systems in terms of low noise transmission and low water hammer effect.

Electrical

As Polypipe polybutylene pipe does not conduct electricity, installations generally require less equipotential bonding than metal systems. Both the IEE and the IoP give guidance on the earth bonding requirements of plastic pipe systems. Where Polypipe polybutylene pipe breaks the continuity of existing metal pipe, which may be used for earthing or bonding, this continuity should be reinstated by afxing permanent earth clips and a section of earth cable between the ends of the copper pipe.

Side-effects

Polypipe believes there to be no side-effects from handling or using its pipes and ttings.

Compatibility

Polypipe polybutylene pipe connects to rigid pipe systems and is compatible with all recommended inhibitors.

For details of compatibility with specic building materials, such as ller foam and wood worm treatments, please consult the Polypipe Technical Hotline on 01709 770000.

Polypipe pipes and ttings can be painted using emulsion or undercoat and gloss. Cellulose based paints, strippers or thinners must not be used.

Durability

Polypipe oor heating products, excluding manifolds and control products, are guaranteed for 50 years against defects in materials or manufacture from the date of purchase (exclusions apply). Visit www.ufch.com to a view a full copy of our current guarantee(s).

TECHNICAL DATA TECHNICAL DATA

40 100 60.9 25.7

45 100 76.2 27.0

50 100 91.6 28.3

55 100 95.0 28.6

40 200 50.8 24.9

45 200 63.6 26.0

50 200 76.3 27.0

55 200 77.0 27.2

40 300* 42.8 24.2

45 300* 53.6 25.1

50 300* 64.3 26.0

55 300* 66.7 26.9

Mean water Pipe Output Surface ﬂoor temperature °C spacing mm W/m2 temperature °C

40 150 61.0 25.8

45 150 68.0 26.3

50 150 79.0 28.1

55 150 101.0 30.1

60 150 124.0 32.0

Mean water Pipe Output Surface ﬂoor temperature °C spacing mm W/m2 temperature °C

40 90 52.0 25.0

45 90 64.0 26.0

50 90 76.0 27.0

55 90 100.0 29.0

60 90 124.0 31.0

Mean water Pipe Output Surface ﬂoor temperature °C spacing mm W/m2 temperature °C

40 225/300 31.7 23.1

45 225/300 40.2 23.9

50 225/300 49.2 24.7

55 225/300 50.0 24.8

60 225/300 52.3 25.0

Mean water Pipe Output Surface ﬂoor temperature °C spacing mm W/m2 temperature °C

50 51

FAULT FINDING CHARTS

Before using this ﬂow chart please ensure that both the primary and under ﬂoor heating systems are full and that all isolating valves are fully open. Please also ensure that the room thermostats are calling for heat.

Hydraulic fault ﬁnding chart

YES

Is the fused spur

switched on?

Is there 230V at

‘L’ terminal on PCB?

Is Green Power

LED illuminated?

Is 230V present on

all T2 terminals?

Is 230V present on

all T1 terminals?

Are the zone valve

and under ﬂoor heating pump

operating?

Is there 230V to NC Boiler

switch live connection?

(Check operation of Volt free relay

connections if using 24V)

Is the boiler ﬁring?Check boiler connection

Turn the fused spur on

Replace 3A fuse in spur

Replace fuse on PCB

(2.5A 230 Vac Type 5x20)

Faulty PCB replace unit

Faulty room thermostat -

replace unit

Relay 1 faulty replace PCB

Relay 2 faulty replace PCB

System operating correctly

Electrical fault ﬁnding chart (master connecting box)

This testing procedure should only be carried out by fully qualiﬁed persons. Testing should be done with all switches on and room thermostats calling.

Fault ﬁnding

complete

Adjust pump speed

and set ﬂow rates

in accordance with

the system design

data as provided

NONO

Is the boiler ﬁring

and the primary

pump operating?

Check for 230V signal to boiler from master

wiring centre

YESNO

Is there hot water

present prior to

under ﬂoor heating

mixing valve?

Check if the under ﬂoor heating zone

valve is open

Electrical fault

(see electrical fault

ﬁnding guide)

Boiler fault

Primary ﬂow and return crossed or

debris in mixing valve

YES

Check 230V signal

to zone valve from

master wiring centre

Under ﬂoor

heating pump

operating

Check 230V signal to

pump from master

wiring centre

Is the system

performing

correctly?

Ensure that manifold

lockshield valves are

fully open

YES

START

YES

NONO

Is hot water passing through under ﬂoor

heating manifold?

Check temperature

adjustment on

under ﬂoor heating

mixing valve

YES

NONO

Is there a visible ﬂow

present through

all under ﬂoor

heating circuits?

Check if the

actuators are open

Electrical fault

(see electrical fault ﬁnding

Pump fault

Zone valve fault

Electrical fault

(see electrical fault

ﬁnding guide)

Actuator fault

Check 230V

signal to actuator

from slave unit

YES

START

52 53

FLOOR TYPE

ROOM AREA

CONTROL UNIT

Selecting the right Polypipe Floor Heating Pack couldn’t be easier. Simply decide whether the project is:

(a) A single room (b) A whole house solution (c) Requires our design

Complete each of the 3 steps for your chosen project

Order the resulting pack number or submit your design request to polypipe

SOLID So OVERLAY™ O OVERLAY™ LITE OL

12 20 30

ZRU

L xW

House Pack/Room Name Area (m2) No of Circuits 1 / 15m2 / Room Control Required (Yes/No)

Room 1

Room 2

Room 3

Room 4

Room 5

Room 6

Room 7

Room 8

Total control zones

Please return your completed form to:

Floor Heating Design, Polypipe Building Products Ltd, 1 Neale Road, Doncaster, DN2 4PG, England

Tel: 01709 770000 Fax: 01709 770001

www.ufch.com

FLOOR HEATING SYSTEMS PRODUCT SELECTOR

FLOOR HEATING - PRODUCT SELECTOR

Or you can visit www.ufch.com to use the online Floor Heating Product Selector

HOUSE PACK Note: 5m Overlay™ pack - including Temperature Limiting Valve code: 05B

HOUSE PACK Selection for each Manifold and each Floor Type - max area for each Manifold 100m

Total area

(add total room area)

Total No of Circuits

Accreditations, standards and guarantees

One of Europe’s largest manufacturers of plastic plumbing and heating products, Polypipe Building Products Ltd has developed a unique range of under oor heating solutions. Designed for installation in to both existing and new build projects all Polypipe products are manufactured and tested to highest standards to ensure maximum quality and performance.

For further quality assurance all Polypipe products carry the following Standards and System Approvals:

Manufacturing quality assurance

In accordance with BS ES ISO 9001:2000 (BSI registered rm Certicate FM00318).

Installation standard

To follow the recommendations of BS5955 - Part 8 2001 Plastic Pipework (Thermoplastic Materials).

British standard

Class S Rated to BS7291 Part 1 and Kitemark Licence Number 38148 to BS7291 Part 2.

WRAS Listed in the WRAS Water Fittings and Materials Directory. KIWA/KOMO Certicate numbers K14341, 14342 and 14343.

BBA Polypipe Polybutylene barrier pipe, ttings, accessories

and under oor heating systems are covered by BBA Certicate No. 00/3699.

British Gas - has accepted the Polypipe Polyplumb Class S Polybutylene pipe system as being acceptable for open vented and sealed central heating systems and is eligible for acceptance onto Three Star Central Heating System Cover.

P.B.P.S.A. Polypipe Building Products Ltd is a member of the Polybutylene Piping Systems Association, which is a recognised association of the companies whose aim is to promote the features, benets and best practice installation techniques of polybutylene pipe systems, as well as providing a wide range of technical information and support.

Polypipe is a member of the Underoor Heating Manufaturers Association.

Guarantee

Polypipe under oor heating products, excluding manifolds and control products, are covered by a 50 year Guarantee*, which protects against defects in materials or manufacture of the heating system from date of purchase. This guarantee only applies if the system is installed in accordance with the manufacturer’s recommendations, and is used in a normal domestic operation. This document should be read in conjunction with all other documentation supplied with Polypipe products. If you have any queries, please contact our Technical Hotline on 01709 770000.



FM00318

54 55

Please return your completed form to:

Floor Heating Design, Polypipe Building Products Ltd, 1 Neale Road, Doncaster, DN2 4PG, England

Tel: 01709 770000 Fax: 01709 770001

www.ufch.com

FLOOR HEATING SYSTEMS DESIGN ENQUIRY FORM

CLIENT DETAILS

Project:

Client:

(Polypipe use only)

Project Reference No: Contact:

Address:

Post Code:

Telephone: Mobile:

Designs to be returned to

Client Sender

SENDERS DETAILS

Client: Contact:

Address:

Post Code:

Telephone: Mobile:

UNDER FLOOR HEATING REQUIREMENTS

Manifold Position(s)

(Please also indicate on drawing)

Floor Type

(Solid, Suspended, Floating, MHP, Overlay™, Overlay™ Lite)

Ground Floor

1st Floor

2nd Floor

CONSTRUCTION DETAILS If NOT to current Building Regulations

NOTES

U Value

(W/m2 deg C)

External Walls

Roof

Windows

Websites

www.ufch.com

www.freeyourwalls.com

www.polypipe.com

Literature

Under ﬂoor heating price list

downloadable at www.ufch.com

Plastic plumbing price list

downloadable at www.polyplumb.co.uk

Plastic piping systems sustainability brochure

downloadable at www.polypipe.com

Plastic plumbing brochure

downloadable at www.polypipe.com

OTHER INFORMATION AND LITERATURE

Polypipe Under Floor Heating Systems Technical Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual