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The DATA HIU
Installation Instructions D3
The DATA HIU, Installation Instructions D3 13/06/2017
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The DATA HIU, Installation Instructions D3, 13th June 2017
The DATA HIU, Installation Instructions D3
Wiki Binder, 13th June 2017
About Thermal Integration
Explanation of symbols and abbreviations
Overview of Components and Connections
Options
Dimensions
Technical Data
Application
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General Plumbing Requirements
General Wiring Requirements
Schematic Layout
Wiring Diagram
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Installation Requirements
Installation Setup
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Stage 1 - Pre-Fix Bracket Positioning
Stage 2 - HIU Preparation
Stage 3a - Fixing HIU
Stage 3b - Pipework Connections
Stage 4 - Fitting a Heat Meter
Stage 5 - Filling the Heating System
Stage 6 - Bleeding the Unit
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Stage 7 - Programmer and Room Thermostat Connection
Stage 8 - Connect Power
Adjusting Settings
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Securing the Casing
Service & Inspection
Draining the Unit
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Pump Settings (Wilo)
Pump Settings (Grundfos)
DHW Recirculation Pump (Optional)
Differential Pressure Valve (Optional)
Troubleshooting (End Users)
Troubleshooting For Technicians
Heat Meter
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Dirt and Air Separation
Guarantees and After Sales
DATA EC Declaration
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The DATA HIU, Installation Instructions D3, 13th June 2017
About Thermal Integration
About Us
We design and manufacture pre-fabricated Hot Water and Central Heating Cylinders, Thermal Stores, Buffer Tanks and Heat Interface
Units to suit almost any domestic or commercial application. Our range of products is the end result of over 20 years of continuous
development and improvement in heating technology. We hold to the philosophy that all customers deserve our best level of service for
the life of the product, as well as complete honesty throughout the product selection process. We hold a significant number of patents
in the fields of water storage, heat exchange, and the networking of communal heating systems, and continue to push the boundaries.
As well as the most comprehensive range of hot water systems in the UK, our headquarters in Sudbury also offers the UKs largest
renewables training centre, including the first HETAS training and test centre, with working wood, pellet and log biomass rigs, as well
as solar. There is also an extensive district heating demonstration and test facility attached to the factory, with the factory building
services running from a twin pellet biomass boiler installation, buffer storage, and HIUs to provide services. The entire facility is
controlled using our in-house IHIU Control Systems that allow any of our products to be network connected, with online monitoring and
dashboard facilities.
For a complete history of the company please read History of Thermal Integration Limited on Heatweb Wiki.
Product Range
Heat Interface Units
Standard Cylinders
Shortened Cylinders
Buffer Cylinders
Combination Cylinders
Mains Pressure Thermal Stores
Mains Hot Water Conversion Kits
Prefabricated Systems
Plate Heat Exchangers
Boiler Conversion Kits
Control Systems
Knowledge Base
To make the dissemination of technical material as simple as possible, we publish all our documentation through an online document
storage system, the Heatweb Wiki. Links to further information may be found throughout documents.
Useful Contacts
Commercial Sales and Operations: 0845 2411441
Specflue Sales: 0333 9997974
Web Sites
http://www.heatweb.co.uk Company Website
http://www.systemdesigner.co.uk System Designer
http://wiki.heatweb.com/wiki Heatweb Wiki
http://www.heatweb.info Monitoring software and online APIs
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The DATA HIU, Installation Instructions D3, 13th June 2017
Explanation of symbols and abbreviations
Symbols
Abbreviations
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The DATA HIU, Installation Instructions D3, 13th June 2017
Overview of Components and Connections
1 Primary circuit strainer
2 Back casing
3 Primary flow temperature sensor
4 Heat meter sensor pocket
5 Automatic air vent (central heating)
6 Electronics 230 V
7 Electronics 24 V
8 Heat exchanger (central heating)
9 Domestic Hot Water Temperature sensor
10 Heat exchanger (DHW)
11 Central heating pump
12 Domestic Hot Water control valve
13 Domestic Hot Water primary return temperature sensor
14 Central heating strainer
15 Filling point
16 Flow sensor
17 Pressure/temperature gauge
18 Temperature/pressure sensor central heating supply
19 Pressure relief valve (3 Bar)
20 Temperature sensor central heating primary return
21 Heat meter spool piece
22 Central heating control valve
23 Expansion vessel
24 Expansion vessel bleed valve
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The DATA HIU, Installation Instructions D3, 13th June 2017
Options
The unit has several options available depending on requirements. The basic unit can be equipped with any combination of
thefollowing:
Option A1: Spool piece, used when neither option A2 or A3 are required.
Option A2: Landlord security valve, allows the landlord to remotely isolate the unit from the district heating network if required.
Option A3: Differential pressure control valve, to balance differential pressures between the primary flow and return. Only required
where the differential pressure exceeds 250kPa. (Max 450kPa)
Option B: Water hammer arrestor, reduces water hammer within the DHW circuit.
Option C: DHW recirculation unit, to provide constant circulation of DHW throughout the property in order to allow quicker
response times at the tap where extended pipe runs are unavoidable. Note: The unit must be set to 'Comfort' Mode by the installer,
when this option is fitted.
Option D: Decorative casing, attractive white painted steel casing.
Option E1: Standard Output Domestic Hot Water, up to 65kW (at 10-60C)
Option E2: Plus output Domestic Hot Water, up to 80kW (at 10-60C)
Option F: Flushing Bypass for connecting to the primary flow and return pipework (External to the unit)
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The DATA HIU, Installation Instructions D3, 13th June 2017
Dimensions
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The DATA HIU, Installation Instructions D3, 13th June 2017
Technical Data
Description Data
Nominal primary supply temperature 80C
Maximum primary supply temperature 85C
Minimum primary supply temperature 55C *
Nominal DHW supply temperature 55C
DHW Set Range 45C to 60C
Return Temp Limit Range 35C to 65C
CH Limit Range 30C to 80C
Primary connections Female / 18mm
Mains & DHW connections Female / 18mm
Central heating connections Female / 18mm
Pressure relief 15mm
Domestic Hot water heat exchanger (DHW) E8LAS40
Central heating heat exchanger (CH) E8LAS40
Maximal primary differential pressure (without dP regulator) 250kPa
Maximal primary differential pressure (with dP regulator) 450kPa
Minimal primary differential pressure 50kPa **
Pressure class DH circuit PN16
Pressure class CH circuit (3 bar safety valve) PN10
Pressure class DHW circuit PN10
CH Maximum working pressure 2.5 Bar
Casing width 490mm
Casing height 640mm
Casing depth 275mm
Casing Material EPP Expanded Polypropylene
Maximum Heat Losses 50W (1.2 kWh/day)
Typical Heat Losses (DHW Only, Keep Warm) 25W
Weight (basic version) 24kg ***
Electrical supply info 230V 50Hz
Fuse ratings 3 Amp
Sensor DHW NTC 10kohm @ 25C
Keep Warm Modes Economy / Comfort
Max Return Temperature during Keep Warm Mode DHW Setpoint - 2C
.* Minimum required DH supply temperature is DHW setpoint + 5C with a minimum of 55C.
.** Depends on requested DHW output and available DH supply temperature.
.*** Unit weight may vary depending on the optional components built into the unit
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The DATA HIU, Installation Instructions D3, 13th June 2017
Application
The Data twin plate HIU is used to provide hot water and central heating in properties connected to a district heating systemusing a
centralised boiler. Please keep the following conditions in mind during installation:
The unit must be installed in a frost free area.
The unit must not be exposed to direct sunlight.
Ambient temperature should be between +5C and +40C.
Humidity should be between 10% and 85%.
The unit must be connected to a fused double pole isolator.
The unit uses 230 VAC. Use caution when handling. Contact may lead to shock, burns or electrocution.
Temperatures of components in the unit and connected to the unit can reach high temperatures. Contact may lead to burns.
Status indicator LED
Green blinking (slow): Normal condition
Green blinking (fast): Heating demand
Blue blinking: Domestic Hot Water Mode / Tap draw-off
Red blinking: Error
White continuous: Service mode (installer only)
No LED: HIU is switched off
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The DATA HIU, Installation Instructions D3, 13th June 2017
Operation
Central Heating
The heat exchanger physically separates the district heating network and the central heating circuit. The application minimises the
riskof contamination of district heating water as well as the risk and consequences of leakage in the central heatingsystem.
Components, pipes and radiators in, and connected to the unit may be hot. The DATA heat interface unit is designed for use with
centralised heating systems up to 85C. The pipes and components in the unit and the pipes and radiators in the central heating
installation can reach temperatures of 80C and contact may lead to burns.
Domestic Hot Water
The unit is equipped with single walled plate heat exchangers. The front heat exchanger transfers the heat from the district
heatingsystem to the DHW. The electronics within the unit, together with domestic hot water control valve, temperature sensors and
flowsensor, regulate the temperature of the hot water to it's set point (As Standard 55C).
Each HIU has two domestic hot water keep hot modes, Eco or Comfort mode. These can only be selected during commissioning or by a
trained engineer.
The default setting is Eco mode, and this can be specified to run for 0 minutes (which turns the feature off all together), 15, 30, 60 or
120 minutes after the last hot water draw off. In Eco mode the heat exchanger is kept to a specified temperature (between 25 and 60
Deg C) for the selected period of time and after this period of inactivity has elapsed the stepper motor closes completely and the
temperature in the domestic hot water circuit is allowed to drop through natural dissipation to minimize energy consumption. If a hot
water draw off is made any time throughout the Eco mode function the unit will deliver hot water as usual and the Eco mode function
will begin counting down for the selected time once again.In Comfort mode the heat exchanger is continuously supplied with a trickle of
primary water for quicker hot water delivery, however energy consumption will be slightly higher than if the unit was set in Eco mode.
To prevent legionella from growing the heat exchanger is heated to 57C for at least 30 minutes every 24 hours. (it is not possible to
specify the time at which this occurs)
The hot water temperature is regulated to approximately 55C. If there is a power outage during DHW draw off, units not fitted
with a landlord security valve will stop regulating the hot water temperature. This may lead to a hot water temperature that is
higher or lower than 55C. Hot water can cause burns.
Priority Switching
The unit is fitted with domestic hot water priority switching. When hot water is drawn off, the central heating control valve will
close,diverting all primary flow to heat the domestic hot water circuit. Primary flow to the central heating is cut off during hot water
delivery.Primary flow to the central heating is resumed after the hot water draw off has finished.
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The DATA HIU, Installation Instructions D3, 13th June 2017
General Plumbing Requirements
NEW COMPLETE SYSTEM INSTALLATIONS When carrying out a completely new heating system installation in a new build property
or a first time installation in an existing property, then the heating system must conform to current building regulations Part L1a. All
new domestic heating systems must have a minimum of two heating zones. Each of these zones should be controlled by a thermostat
and zone valve. Alternatively individual electronically controlled Thermostatic Radiator Valves may be fitted. If domestic hot water is
provided by a storage system then the storage system or cylinder will require separate time and temperature control.
All radiators must have TRV's fitted in all rooms except bathrooms and any rooms where a thermostat is located. The exception to this
are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling
can be controlled as one zone.
EXISTING INSTALLATIONS: When carrying out boiler replacements on an existing system, the regulations do not require separate
zoning of the upstairs and downstairs and compliance with the regulations can be achieved by a single room thermostat or
programmable room thermostat. It is however recommended that TRV's are fitted to all rooms except the bathrooms and the room
where a thermostat is located.
The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building
Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document
635 (The Electricity at Work Regulations 1989) and any other local requirements.
BRITISH & IRISH STANDARDS Where no specific instruction is given, reference should be made to the relevant British and/or Irish
Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
EN12828 Central heating for domestic premises
BS7593 Treatment of water in domestic hot water central heating systems
ECTI National rules for electrical installations
Potable water: All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic
water system must be approved by WRAS.
CH Water: Artificially softened water must not be used to fill the central heating system.
FITTING AND MODIFICATIONS: Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer. Any misuse or unauthorised modifications to the appliance or associated components and systems could invalidate the
guarantee and may lead to serious injury or even death. The manufacturer accepts no liability arising from any such actions, excluding
statutory rights.
SERVICING: The end user should be advised to have the system serviced annually by a competent engineer. Contact Thermal
Integration Ltd for a list of approved engineers. Approved spares must be used to help maintain the economy, safety and reliability of
the appliance. The service engineer must complete the Service Record after each service.
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General Wiring Requirements
These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. Component specific
electrical information may also be supplied in support of these instructions, however if there is any doubt please contact Thermal
Integration Ltd. (Tel: 0845 2411441)
FAILURE TO INSTALL APPLIANCES CORRECTLY COULD LEAD TO PROSECUTION.
The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building
Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document
635 (The Electricity at Work Regulations 1989) and any other local requirements.
BRITISH & IRISH STANDARDS: Where no specific instruction is given, reference should be made to the relevant British and/or Irish
Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
EN12828 Central heating for domestic premises
BS7593 Treatment of water in domestic hot water central heating systems
ECTI National rules for electrical installations
Potable water: All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic
water system must be approved by WRAS.
CH Water: Artificially softened water must not be used to fill the central heating system.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
Danger of short circuit: When connecting the cables ensure that no cable pieces fall inside the control panel.
The Mains supply to the appliance must be through a fused double pole isolator situated next to the appliance. The isolator must have a
contact separation of 3mm minimum in all poles and should isolate the appliance and all associated controls.
Unless otherwise stated, all Heat Interface Units should be connected to a mains 230V 50Hz Supply fused at 3 Amps.
All electrical connections with the Heat Interface Unit control panel are clearly marked as follows:
L = Live 230V
N = Neutral
E = Earth
Any additional mains cable should comply fully with the current I.E.E. wiring regulations. It must have a minimum section of 0.75mm
and be capable of withstanding a minimum of 85C.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Schematic Layout
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The DATA HIU, Installation Instructions D3, 13th June 2017
Wiring Diagram
Power Supply
The heat interface unit is equipped with a wiring centre that converts the 230 VAC power supply to 24 VDC and powers the CH pump
and optional DHW pump. It also houses the main fuse for the unit.
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Room thermostat
The unit can be equipped with a on/off thermostat that has potential free contacts or a Honeywell round on/off (T87G2014)
thermostat with power stealing technology.
Full Wiring Diagram with Ethernet Billing
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The DATA HIU, Installation Instructions D3, 13th June 2017
Installation Requirements
Components, pipes and radiators in, and connected to the unit may be hot. The DATA heat interface unit is designed for use with
centralised heating systems up to 85C. The pipes and components in the unit and the pipes and radiators in the central heating
installation can reach temperatures of 80C and contact may lead to burns.
To ensure the life expectancy of the unit, the system must meet certain requirements. Keep following conditions in mind during
installation:
Maximum pressure supplied by the district heating network is 10 bar.
Maximum differential pressure supplied by the district heating network is 250 kPa. (450 kPa when differential pressure valve is
fitted)
Maximum supplied temperature by the distict heating network is 90C.
Minimal supply temperature is setpoint DHW + 5C.
Central heating
Before the unit is commissioned, the central heating circuit must be fitted with an automatic bypass valve to maintain a minimal
flowrate and regulate pressure across the system. The valve must be installed between the central heating supply and return, noting
thedirection of flow.
ABV = Automatic Bypass Valve
NOTE For optimal energy efficiency and comfort, it is of the utmost importance to hydraulically balance the CH system correctly. For
the same purpose it is advisable to design the CH system in such a way that the CH return temperatures are as low as possible.
* Artificially softened water must not be used to fill the central heating system
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The DATA HIU, Installation Instructions D3, 13th June 2017
DHW Recirculation Unit
The DHW recirculation unit is an available option within the unit. The circulation system connected to the unit must not contain
anyclosable valves. Applying valves to the system can cause the pump to overheat due to insufficient flow.
Keep following condition in mind during installation:
Maximum pressure supplied by the domestic water circuit is 10 bar.
All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system
must be WRAS approved.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Installation Setup
Parts Supplied and Required for Installation
Connections
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 1 - Pre-Fix Bracket Positioning
The following dimensions for for the extended pre-fix kit.If a flushing by-pass is to be fitted, please refer to the relevant page.
1.Mark out the wall with the fixing points using the dimensions shown below.
2.Drill holes using a suitable drill bit to suit wall plugs provided in accessory pack.
3.Using a level, fit first fix brackets to wall.
4.Continue with external pipework as required. With isolating valves closed the systems can be filled for testing.
Mounting to a plywood wall:Minimal plywood thickness must be 18 mm. Make sure that the back wall is at least 50 mm wider than
the unit to ensure a proper support. Make sure the drill markings are aligned and leveled. Drill holes of 4 mm on the markedlocations
40 mm deep. 4 holes are drilled for the fix rail unit and another 4 for the unit. Mount the fix rail firmly to the wall using the enclosed
screws.
Mounting to a concrete wall:Make sure the wall is robust and of good quality. Avoid hollow walls and make sure that the screws are
not placed in the flushings of a brick wall. Drill holes of 10 mm on the marked locations 60 mm deep. 4 holes are drilled for the fix rail
unit and another 4 for the unit. Mount the fix rail firmly to the wall using the enclosed screws and plugs.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 2 - HIU Preparation
1.Remove casing carefully. If the unit is supplied with a security bracket, this will first need to be removed.
2.Remove bag of accessories.
3.Remove protective caps from connections
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 3a - Fixing HIU
Please use the enclosed screws and plugs to mount the unit.
The fixing must be able to withstand at least the unit weight. Please allow for a minimum of 30Kg.
There are 4 lower connections if the Domestic Hot Water recirculation unit is not fitted.
1.Place washers into lower union connections.
2.Lift the HIU into position and with unit slightly tilted forwards, position onto lower first fix bracket, making sure washers remain in
place.
3.Tighten connections.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 3b - Pipework Connections
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 4 - Fitting a Heat Meter
Units are typically supplied with heat meters factory fitted as per requirements, however a heat meter can be fitted by following these
steps.
1. Remove Spool Piece
2. Install Heat Meter
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 5 - Filling the Heating System
The method of filling the CH system must comply with the current water supply (water fittings) regulations and use approved
equipment. For GB Please refer to Guidance G24.2 and recommendation R24.2 of the water regulations guide. For IE Please refer to the
current edition of I.S. 813 "Domestic Gas Installations".
A WRAS approved filling loop should be used for connecting the mains water supply to the CH system so that the system can be filled
on installation or whenever water pressure has been removed for system modifications, etc. An approved double check valve must be
permanently fitted to the mains water circuit to provide backflow prevention and the temporary filling hose must be removed and
connections capped after use.
Failure to isolate and disconnect the temporary filling hose after use, may result in the central heating system being over-pressurised
and could cause damage to central heating components.
The nominal operating pressure of the central heating system should be between 1 and 2 Bar.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 6 - Bleeding the Unit
To ensure the unit functions properly, it must be bled first. This can be done from two places within the unit. The system must also be
bled at the radiators.
1.Disconnect the power to the unit
2.Bleed the unit at the points shown below and the bleeding points connected to the radiators.
3.Start at the lowest bleeding point and work upwards ending at the highest point in the property.
4.Bleed the system until all air is expelled.
5.Option for quick filling CH system (only at position 2): For quick filling of the CH system, turn the red cap of the automatic air vent
counterclockwise. Set the red cap in the original position after filling.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 7 - Programmer and Room Thermostat Connection
The unit can (optionally) be connected to a programmer / room thermostat, to control central heating timing and / or temperature.
Connecting the programmer / room thermostat:
1.Locate the brown and white twin cable (600mm Long) at the back of the HIU electronic controller, remove and discard the
temporary coupler plug.
2.Connect a VOLT FREE programmer / room thermostat (sold separately) across the brown and white cables.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Stage 8 - Connect Power
1. Close all isolation valves in the property.
2. Check all coupling nuts for leakage. (nuts may become looseduring transport)
3. Make sure the electronics are securely mounted to the frameand avoid cables and pulse pipes from fouling the casing.
4. Connect the units power cables (A) to the power outlet.
Blue cable: N (Neutral)
Brown cable: L (Live)
Green/yellow cable: E (Earth)
5. Slowly open the filling loop valves to pressurize the unit andcheck for leakage.
6. Switch on the power supply to the unit. The LED should show agreen blinking light (B).
7. Slowly open the district heating flow valve (C) and check forleakage.
8. Slowly open the district heating return valve (D) and check forleakage.
9. Slowly open the central heating flow valve (E).
10. Bleed the system. Start at the lowest point and work your way tothe highest bleed point. Please refer to the chapter Bleeding
thesystem.
11. Slowly open the central heating return valve (F).
12. Check that the central heating controls are calling for heat andthe system begins to warm.
13. Slowly open a hot tap in the property. Check to see if the unitsLED shows a blue blinking light (B). Open the hot tap completelywhen
the system is fully bled and leave it running forapproximately 5 minutes. After 3 to 5 minutes check the watertemperature at the tap is
between 45C and 60C (Depending on thesetpoint).
14. Bleed the unit (G)Please refer to the chapter Bleeding the unit.
15. Close the hot tap in the property. The LED will now show a greenblinking light (B)
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The DATA HIU, Installation Instructions D3, 13th June 2017
Adjusting Settings
The Data requires connection to either a PC running the commissioning software, or by the use of an iHIU Controller, in order to
adjustsettings.
End users cannot adjust settings, unless an iHIU Controller is used.
PC Software
The software is made freely available, along with training, to registered commissioning engineers. Please contact Thermal
Integrationfor further information.
The software allows one to adjust the following settings:
Setting Options Default
Domestic Hot Water Temperature 45C to 60C 60C
Primary Differential Pressure Auto or Manual from 0.3 to 2.0 bar Auto
Warmup Boost Flow Rate 8 to 20 l/min 12 l/min
Return Temperature Limit Disabled or Enabled from 35C to 65C Disabled
Maximum Central Heating Temperature 30C to 80C 80C
Central Heating Pump Timeout 0 to 30 minutes 15 minutes
iHIU Controller
The iHIU Controller is a miniature Linux web server that can be supplied separately to provide more advanced control and monitoring of
the Data HIU. The controller is typically mounted within the casing of the HIU, with an option for a display on the front of the HIU.
The controller provides a WiFi zone, and can log onto existing networks through either WiFi or Ethernet to gain access to the internet.
The HIU can then be controlled directly from other devices on the local network, such as smartphones. Once connected to the internet
the system can provide remote control and monitoring services, as well as many other features, some of which are listed below:
Browser based cross platform interface that adjusts to screen size
Allows setting of all the parameters available to the PC software, except via a browser
Control over central heating as well as other settings via Google Calendar
Remote commissioning
Remote fault alarms and message forwarding vi email or SMS
Voice control over services via Android app
Connection to Energy Saving Trust's Embed Database for free and secure online storage of all system data
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The DATA HIU, Installation Instructions D3, 13th June 2017
Securing the Casing
To secure the unit, a metal security casing is fitted. The casing will obstruct from removing the EPP casing without damaging the seal. It
also functions as a mount for the display of the heat meter.
1.Mount the display of the heat meter onto the metal security casing.
2.Move the metal security casing into position (1) and guide the heat meter cables through the casing. Make sure the cables are not
obstructed or tangled.
3.Check to see if the metal security casing is aligned with the EPP casing (2).
4.Fix the metal security casing with the enclosed screw and seal. Make sure the order of assembly is as shown (3).
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Service & Inspection
To ensure the unit functions properly, it is advised to periodically inspect the installation.
Maintenance and repairs should be carried out by recognised personnel only.
Remove the power from the unit when performing maintenance and/or repairs.
Connect the flow and return valve from the district heating network.
Connect the flow and return valve on the unit.
Check the unit for leaks.
Check the primary and central heating strainer for debris and clean if necessary.
Check valves for debris and clean if necessary.
Check the unit operates satisfactorily in domestic hot water and central heating modes.
The casing can be cleaned with a damp cloth. Do not use detergents of any kind.
CAUTION! The unit uses electrical components (230VAC and 24VDC). These components must stay dry at all times. Contact with
these energized components can result in an electrical shock, burn, or electrocution.
Prolonged Absence
Do not switch off the unit during long absence or holiday. To prevent frost damage within the unit or the distribution network, the
radiator and shutoff valves MUST remain open. Radiators can be switched to the frost protection position (slightly opened) and/or the
room thermostat lowered to a MINIMUM of 10C. It is recommended to flush all water tapping points and showers for at least 2
minutes after a long period of absence.
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Draining the Unit
Should the unit need draining, please follow the below steps.
1.Disconnect the power to the unit
2.Open all radiator valves. When thermostatic valves are C fitted, switch them towards their maximum setting.
3.Close the district heating flow and return valves (A)
4.Remove the units front casing (B)
5.Open the bleeding points in the unit (C). Please refer to the chapter Bleeding the unit.
6.Connect a hose to the fill/drain valve (D)
7.Drain the unit by opening the fill/drain valve (D). The bleeding points on the radiators must be open during this procedure.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Pump Settings (Wilo)
The heat interface unit is fitted with one of two central heating pumps. The pumps can be
adjusted to fit the end users situation. By default, the pumps are placed in the maximum
setting with a constant differential pressure.
Adjustments to the pump settings should be done by recognised personnel only. Please use
caution when adjusting the unit. Parts can be hot or energized. Contact with these parts may
lead to shock, burn or electrocution.
The Wilo pump is fitted with Red Knob technology. The knob opens the possibility to toggle
between different settings:
1. Selecting the setup type
2. Setting up the desired differential pressure (H)
3. Activating the pumps bleeding function
Setting up Pump Head
Bleeding
The pump will bleed itself at first
startup. If the pump does not
bleed itself, follow the steps
below:
Pump settings are marked in metres
pressure head, up to a maximum of 8m.
The differential pressure setting
increases the head the pump generates
as the flow accepted by the system
increases. This setting can assist in
reducing noise at low loads, as well as
allow for long pipe runs where pressure
losses become more significant at
higher loads.
1. Switch to bleeder mode
2. Bleeder function will start
after approximately 5
seconds and will take about
10 minutes to complete
3. When bleeding is finished,
switch the red knob back to
the preferred setting
The constant pressure setting
maintains a set head at all flow rates,
modulating the pump up and down as
load increases to maintain the same
head.
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Pump Settings (Grundfos)
The Grundfos pump has 3 control modes (proportional pressure, constant
pressure and constant curve). Each control mode has 4 settings to choose
from. The user interface has 1 push button, one red/green LED and 4
yellow LEDs.
Settings
When you switch on the pump, it runs with the factory pre-setting or the last setting. The display shows the current operation status.
1.Press the button to switch to the setting view. The LEDs show the current setting for 2 seconds. (The default setting is curve 3)
2.Release the button for more than 2 seconds. The user interface shows the current performance in "operation status".
3.Press the button for more than 2 seconds and the pump switches to "setting selection". The LEDs flash and show the current setting
mode. Please note that if the key lock is disabled, the pump will not switch to "setting selection". In this case, unlock the key lock by
pressing the button for more 10 seconds.
4.During a period of 10 seconds, press shortly on the button and the pump switches to the next setting.
5.To select between the settings, instantly press the button until you find the setting you want. If you pass a setting, you need to
continue until the setting appears again as it is not possible to go back in the settings menu.
6.Release the button for more than 10 seconds and the user interface switches back to the performance view and the last setting is
stored.
7.Press the button and the display switches to the setting view and the LEDs show the current setting for 2 seconds.
8.Release the button for more than 2 seconds and the user interface switches back to the performance view.
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Performance View
While the pump is running, the first LED will show a green light. The following 4 LEDs will indicate the power consumption as shown in
the table below.
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The DATA HIU, Installation Instructions D3, 13th June 2017
DHW Recirculation Pump (Optional)
The domestic hot water circulation pump is an available option within the unit. The
pump is added to minimize delay in the delivery of domestic hot water at the draw off
point in a closed DHW circulation circuit. It is generally used in systems where the
domestic hot water needs to travel greater distances to its draw off point.
Adjustments to the pump settings should be done by recognized personnel only.
Status indicator LED
LED on (continuously): Normal operation (pump is running)
LED blinking short, long: Error due to low voltage
LED blinking short (4x), long: Error due to pump speed feedback
LED blinking short (3x), long: Error due to high temperature
LED blinking short (5x), long: Pump rotor is blocked
LED On 200 msec., Off 200 msec., On 200 msec. Air venting
LED On 50 msec., Off 50 msec., On 50 msec. Stand-by
Operation errors
Problem Cause Solution
Pump not running Not connected or connected correctly Connect correctly
Pump too hot, dry operation or overheating
protection active
Pump is blocked Contact your supplier
Pump is noisy Not thoroughly air vented Air vent the pump
Foreign objects in pump Contact your supplier
Worn bearing Replace pump
Air venting the pump The pump has an air venting function that can be activated by
turning the knob to position 7 for 5 seconds. Afterwards the desired position can be
chosen. The procedure will take about 10 minutes. The procedure can be canceled by
switching to position 3 and then back to position 7. Audible flow noises indicate that
there is still air in the pump. Should this be the case the air venting procedure needs to
be repeated.
Pump settings The circulation pump has 7 settings to choose from to accommodate
different situations, position 1 being the lowest and 7 the highest setting.
Allow pump to cool down, pump restarts
automatically
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The DATA HIU, Installation Instructions D3, 13th June 2017
Differential Pressure Valve (Optional)
The DATA HIU comes as standard with a function to learn the differential pressure of the primary system during operation, adjusting
its performance characteristics to suit. This self learning feature works by examining the effect of a valve movement compared to
known characteristics, and hence determining what the differential pressure actually is. The self learning feature takes three
seconds to perform, and is done every time a tap is opened and temperatures stabilise.
For DH systems with a differential pressure exceeding 250 kPa (with a maximum of 450 kPa), the option of a pre-mounted adjustable
differential pressure control valve is available. The optionally fitted differential pressure control valve has a control range of 20 to 60
kPa and has DN20 bore. For optimal functioning of the HIU, the adjustable differential pressure control valve is set at its maximum of
60 kPa (default setting).
Adjustments to the differential pressure valve settings should be done by recognized personnel only.
The valve is easily set by means of a 4 mm hexagonal key. The maximum setting of 60 kPa is reached by turning the hexagonal key
clockwise. The number of turns needed to adjust the valve to its maximum setting depends on what the current setting is. The maximum
number of turn is 20, running from its minimum to maximum setting.
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The DATA HIU, Installation Instructions D3, 13th June 2017
Troubleshooting (End Users)
What can you do?
Always take in account the safety of yourself and others when performing a troubleshoot.
Leakage
1. Close all valves on the plumbing bracket under the unit and the mains cold water feed.
2. Contact your engineer.
Central Heating Circuit does not warm up
1. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.
2. Make sure the valves on the plumbing bracket are open (handle in vertical position).
3. Check radiator valves are open and calling for heat.
4. Check the programmer is set to ON, and calling for heat.
5. Set the room thermostat higher.
6. Problem solved? If not, contact your engineer.
No domestic hot water
1. Check that the mains cold water valve is open. If not, open the main valve.
2. Problem solved? If not, contact your engineer.
Tap water does not warm up
1. Ensure that all valves on the plumbing bracket under the unit and the main valve are open.
2. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.
3. Problem solved? If not, contact your engineer.
Sound
NOTE: It is normal that the HIU makes noise when hot water or heating are active. Also, the electronic valves will make a light
(buzzing) noise during movement. If the HIU starts to make any loud or disturbing noises, contact your installer.
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PDF Binders, Installation Instructions
Troubleshooting for technicians
Leakage - Close all valves on the fix rail and clos the main water supply valve.
Coupling nut leaking.
Temperature sensor leaking.
The differential pressure pipe from the
differential pressure regulator is leaking.
Other components/pipes are leaking. Component/pipeis damaged. Replace component/pipe.
Central heating does not warm up.
Radiators do not warm up.
No water at hot tap.
No water at hot tap.
Hot tap water not at right temperature.
Hot tap water does not warm up.
Option:Tap water circulation circuit does not
warm up.
Casing does not close properly.
Casing will not close properly.
Other defects - Note: it is normal for the unit to generate light noise during tapping or heating operations.
Rattling noise. Red or Green flashing LED Flow sensor installed incorrectly. Install flow sensor correctly.
Complaint LED Indication light Cause Solution
Coupling nut is loose. Tighten coupling nut.
Gasket is missing. Fit gasket.
O-ring is missing. Replace temperature sensor.
O-ring is damaged. Replace temperature sensor.
Coupling is loose. Tighten coupling.
Differential pressure pipe is damaged. Replace differential pressure pipe.
LED does not light.
Blue flashing LED. Tap is open, unit is in tapping mode. Close tap.
Red flashing LED.
White flashing LED.
LED not lit.
Green flashing LED. Tap flow rate too low,minimum 1l/min has not been reached. Increase tap to 2l/min by opening tap further.
Red flashing LED.
LED not lit.
No power at power source. Check power source.
Unit is not connected to power source. Connect unit to power source.
Power cables not properly connected to main control board. Connect power cables to main control board.
Fuse is broken. Check for any short circuit problems and replace fuse. (3A)
Failure in electronics. Contact your supplier.
Sensors are not connected/bad contact. Check cable connections and connect sensors properly. Then restart
Sensor(s) defect. Replace broken sensor then restart electronics.
Possibly faulty electronics or cables. Contact your supplier.
Unit is in service mode.
No heating demand from room thermostat. Set the room thermostat higher than actual room temperature.
Radiator valves are closed. Open radiator valves.
Isolation valves on first fix rail are closed. Open isolation valves on first fix rail.
Thermostat cable not properly connected to room thermostat. Make sure the room thermostat is connected properly.
Short circuit connector of the room thermostat is not connected
/missing (when HIU is NOT connected to a room thermostat)
Air in the central heating system. Bleed the HIU and the central heating system.
Pressure in the central heating circuit is too low. Set CH pressure to 2bar. Check for leakage in the CH system or a
Pressure/temperature of the district heating system in not in
accordance with specifications.
Central heating pump not active. (LED on pump not lit) Check pump cable is properly connected to the electronics.
Central heating pump jammed/broken. Contact your supplier.
Optional anti-fraud valve is closed. Valve not connected/powered. Check billing credit status, or valve is
Optional differential pressure valve is poorly adjusted. Adjust valve correctly.
Filters are clogged. Check and clean filters.
CH heat exchanger is clogged. Replace CH heat exchanger.
Control valve cables are mixed up. Connect cables correctly. (Orange/red connector must be connected
Possible defect in control valve. Replace control valve.
No water pressure.
Unit not connected to power source. Connect unit to power supply.
No power at power source. Check power source.
Power cables not connected to main control board. Connect power cables to main control board.
Sensors not connected/bad contact. Check cable connections and connect the sensors properly then
Sensor(s) defect. Replace broken sensor then restart
Possible defect in electronics/cables. Contact your supplier.
Supply and return valves are closed. Open supply and return valves.
Pressure/temperature of the district heating system is not in
accordance with specifications.
Filter is clogged. Check and clean filter.
DHW heat exchanger is clogged. Replace DHW heat exchanger.
Cables of control valve are mixed up. Connect cables correctly. (Green connector must be connected to
Possible defect in control valve. Replace control valve.
Fuse is broken. Check for any short circuit problems and replace fuse. (3A)
Power supply cable of the DHW circulation pump is not connected. Connect supply cable of DHW circulation pump.
DHW pump jammed/broken. Replace DHW circulation pump.
Electronics failure. Contact your supplier.
Cables trapped between unit and casing. Free cables.
Metal flap securing heat exhcangers not in correct position. Correctly position metal retaining flap.
Heat meter obstructing casing. Connect heat meter correctly.
Electronics not properly positioned. Position electronics correctly.
electronics.
Remove USB cable.
Reset unit by removing then replacing power supply.
Connect the wire ends of the room thermostat connection with a
short circuit connector.
broken expansion vessel.
Check pressure/temperature of the district heating network.
damaged - replace valve.
to CH control valve.)
Check/open main water supply valve.
Check flow restrictor for correct/proper placement.
Flow restrictor clogged/jammed. Replace flow restrictor.
Flow sensor clogged. Replace flow sensor.
DHW heat exchanger is clogged. Replace DHW heat exchanger.
Check-valve jammed. Replace check-valve housing including checkvalve.
restart electronics.
Check pressure/temperature of the district heating network.
DHW control valve.)
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The DATA HIU, Installation Instructions D3, 13th June 2017
Heat Meter
The Zenner Zelsius® C5 ultrasonic heat and refrigeration meter operates with
an innovative ultrasonic technology, specially developed for domestic energy
measurement. Thanks to a combination of modern measuring technology and a
very compact design, this meter is outstandingly suitable for recording all
accounting data for measuring energy consumption in heating and/or
refrigeration plants. The wear-free ultrasonic technology is insensible to
debris, stable over the long term and is also reliable for very low volume flow
rates.
Features and Performance Criteria
Available as heat, cooling or combined heat/cooling meters
Low design height
Wired or wireless M-Bus (optional)
2 or 3 pulse inputs or outputs (optional)
Any installation position (even overhead)
Stores 24 months readings
Powered from M-Bus network with 11-year battery backup
Precise, long-term stable, wear-free
Very wide dynamic range
Conforms to MID, Class 2
Part Codes
ZE101C5 15MM C5 IUF Ultrasonic Heat/Cooling Meter. 0.6m3/h, 110mm body length
ZE102C5 15MM C5 IUF Ultrasonic Heat/Cooling Meter. 1.5m3/h, 110mm body length
ZE103C5 20MM C5 IUF Ultrasonic Heat/Cooling Meter. 2.5m3/h, 130mm body length
ZEC5MBO C5 M-Bus Output
ZEC5WMB C5 Wireless M-Bus Output
ZEC5PUO C5 Pulse/Radio Output
ZE200PO Pocket or Ball Valve 5.2mm, 50mm, 34.5mm
ZE015CO 15mm Couplings G3/4 R1/2 (pair)
ZE020CO 20mm Couplings G1B R3/4 (pair)
Further Documentation
C5 IUF Conformity Cert MID
C5 IUF Ultrasonic Heat Meter Data Sheet
C5 Installation Guide
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The DATA HIU, Installation Instructions D3, 13th June 2017
Dirt and Air Separation
Dirt and Air Separation
Air bubbles and dirt particles are always present in the water of cooling and heating
systems. The dirt can accumulate and cause blockages. The use of filters is not ideal
because these do not trap smaller particles, silt up and then have to be regularly cleaned
or replaced. Air and gases in a system are generally a consequence of activities
performed, micro-leaks and of electrolysis and chemical processes in the
water.Traditional de-aeration devices extract insufficient gases from the water, leaving
microbubbles behind.
Air and dirt in a system cause problems such as unnecessary faults and extra wear or
noise, but also lead to disruption of the system, lower heat transfer and reduced pump
performance. The new Flamcovent Smart, Flamco Clean Smart and Flamcovent Clean
Smart air and dirt separators are now offered as standard alongside all systems to provide
reliable protection of the primary system.
60% better performance compared to conventional air and dirt separators.
Suitable for temperatures of up to 120 C.
Suitable for operating pressures of up to maximum 10 bar.
Unique flow velocities, up to 3 m/s.
Can be used with all kinds of pipework.
Compact dimensions, light weight.
Available in various sizes up to 2".
Extremely low flow resistance and low loss of energy.
Consistent performance throughout its service life.
Flamcovent Clean Smart
FlamcoventCleanSmart_ENG_DEF_2014
Flamcovent Clean Smart Insulated
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The DATA HIU, Installation Instructions D3, 13th June 2017
Guarantees and After Sales
Heat Interface Units (HIUs) carry the following guarantees as standard:
FACTORY WARRANTY
1. The warranty begins on the date of delivery. A dated delivery note will be issued to the customer and a copy will be stored by Thermal
integration.
2. 12 Months Parts and labour - Parts or labour proven to be defective will be replaced / repaired free of charge for a period of 12
months from date of delivery, provided the HIU is installed by a qualified engineer within 6 months of date of delivery.
24 Months Parts Only - Parts proven to be defective will be supplied free of charge (for fitting by others) for a period of 24 months
from date of delivery.
3. Replacement of parts under warranty does not extend the duration of the warranty)
4. Any other costs are not covered by this warranty. All other damages of any nature whatsoever and howsoever arising, are expressly
excluded from this guarantee.
5. The warranty conditions above only apply:
a. In the UK only on items provided exclusively by Thermal Integration.
b. If the product is installed by a Thermal Integration approved engineer in compliance with the installation instructions.
c. The installer must complete the commissioning checklist in full at the time the HIU is installed. This checklist must be returned to
Thermal Integration within 30 days of commissioning. Checklists are enclosed in the HIU installation instructions.
d. If the installation complies with all current and relevant building regulations and codes of practice (including the requirement to
clean the primary and secondary heating systems and add corrosion inhibitor in line with BS7593:2006)
e. If the product is used and maintained exclusively according to the manufacturer's instructions and proof of periodic inspection /
maintenance by a Thermal Integration approved engineer is available.
f. If the returned item is accompanied by a fully completed Thermal Integration Warranty Return Form.
6. Excluded are defects caused by:
a. Failure to maintain in accordance with manufacturers instructions
b. Improper use
c. Any attempt at repairs / maintenance by un-qualified persons
d. where parts other than Thermal Integration Genuine Parts have been used in any service or repair
e. Lightning, fire or natural disasters.
f. Deterioration and / or pollution from the district heating system or water network, either domestic hot water or heating side.
g. PH values of the primary medium being less than 7.5 or greater than 9.0.
h. Harmful additives to the heating water.
i. Consumables as specified by us, including but not limited to: hoses, gaskets and batteries
7. Report any faults to your installer, service engineer or Thermal Integration directly. Faulty parts must be accompanied by a fully
completed Thermal Integration Warranty Return form, to be returned to Thermal Integration. Returned items remain the property of
Thermal Integration Ltd.
The Thermal Integration Warranty Return Form can be requested by phone or email. Returns are not accepted unless expressly agreed
in writing.
Transport risk of returned items lies with the sender. The shipping of replacement parts are the responsibility of the supplier.
8. If the HIU breaks down, we may ask you to pay us a deposit before we visit you to repair it. We will return the deposit in full if we find
a fault that is covered by this warranty. We may keep the deposit if we cannot access your property at the time we had arranged with
you to visit or we find other conditions of this warranty have not been met. A responsible adult must be at the property to give our
engineer this access to the HIU.
COMMISSIONING
9. Thermal Integration offer commissioning services across the UK. The service includes:
a. The fulfilment of the defined commissioning instructions
b. Completion and return of site wide commissioning paperwork
c. Rectification of any HIU problems
d. Confirmation of HIU performance to contract specifications
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The DATA HIU, Installation Instructions D3, 13th June 2017
e. Engineer travel and subsistence
Commissioning rates are charged on a whole day basis, and it is the responsibility of the client to ensure:
a. Safe access to properties and HIUs
b. Correct operation of central plant with delivery of heat to HIUs at specified temperatures, flow and pressures
c. All pipework has been correctly tested and flushed
d. Credit on billing system to enable security valve
A minimum 2 weeks notice is required in writing to Thermal Integration before the requested commissioning date.
SERVICE
Technical assistance and engineer backup can be obtained by calling our offices:
Commercial Sales and Operations: 0845 2411441
Specflue Sales: 0333 9997974
FURTHER INFORMATION
The Heatweb Wiki website at www.heatweb.com/wiki contains information on all aspects of HIU design, function, and servicing, and is
always the best place to visit for additional documentation or how to guides.
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The DATA HIU, Installation Instructions D3, 13th June 2017
DATA EC Declaration
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