Floor Mixing Unit Operating Instructions
Contents
1. H 7S NQ fd o PEE r0 a 0 O O O al F7 f l N Hie el Miis 5 i 1 1 Components 1 OM NOD dili 12 13 Flow bar for underfloor heating system with double regulating lock shields Versions with double regulating flowmeters are also available Flow bar for radiator system with 2 to 12 way double regulating lockshields using optional kits 01292316 01292336 2 12 ways Return bar for high temperature circuits with built in valves ready for electrothermic heads available separately using optional kits 01292316 01292336 2 12 ways Return bar for underfloor heating systems with built in valves ready for electrothermic heads available separately Offset mounting brackets 210mm centres 3 port thermostatic mixing valve Return balancing valve Temperature gauge range from 0 to 80 C Manual air vent 2 Drain and filling valves with rotatable connection and safety cap Circulating pump Grundfos UPS 25 60 optional Adjustable over temperature thermostat with wiring box range 30 C to 90 C with off switch position Ball valve kit with2. ing Unit Operat ixing Floor M
3. or without temperature gauge pipe unions in straight or angled pattern Internal blanking plug 1 2 Technical Data Max temperature on primary circuit Maximum operating pressure 85 C 10 bar Graduated scale Thermostatic mixing valve min 1 2 3 4 5 max Temperature range adjustment mixed water 25 C 55 C Kv mixing valve 1 8 3 3 min max Temperature gauge range 0 80 C Maximum thermal capacity available to secondary 15000 W AT 10 C 11000 W AT 7 C 8500 W AT 5 C Circulator pump connection pipe unions 1 1 2 port to port dimension 130mm Manifold size Primary connections q G1 Manifold connections M 24x19 Nominal conditions TH 65 C TC 15 C PH PC 3 bar Qmix 720 I h Test conditions group with Grundfos UPS 25 60 cir culation pump Emmeti connected to open manifold Ap secondary 0 22 0 25 bar For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions 1 3 Pressure drops thermostatic mixer 100 000 e age 2 Knob positions T 10 000 Pos MIN Kv 1 9 5 Pos 1 Kv 2 6 ra Pos 2 Kv 3 2 D 1 000 P
4. Floor M Floor Mixing Unit Installation and Commissioning Instructions 2 Installation 2 3 Circulation pump assembly On the Floor Mixing Unit group install a circulation pump Emmeti Shark N 6 53 or one of equivalent performance and dimensions with rubber gaskets Connect the pump using the 1 1 2 threaded union nuts provided using the rubber gaskets The outlet port of the circulation pump must face downwards Fig E Note For installation in a Metalbox manifold cabinet please ensure that the overall depth inside the cabinet is greater than the overall depth shown in Fig D The pump should be installed with the junction box at the front and the pump outlet downwards The mixing valve has unions at each side see below to allow the mixing valve to be moved and the pump to be fitted Union Fittings 2 4 Electrical connections The Domestic Building Services Compliance Guide recommends the use of a separate flow temperature high limit thermostat for systems connected to a high temperature water supply i e more than 60 C to ensure that the water temperature in an underfloor heating system does not rise above the temperature recommended for the floor Emmeti UK offer a thermostat for this purpose code 28130632 Emmeti UK also offer the EWC 1 wiring centre designed specifically for the connection of electrical components in underfloor heating systems Code U9360010 EWC 1 230V 8 way wiring centre
5. iil 2 1 3 1 4 Dell DD 283 2 4 2 5 2 6 Sal 3 2 3 3 3 4 3 5 3 6 For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions Description Components Technical data Pressure drops thermostatic mixer Schematic system diagram Installation Assembly installation Dimensional data Circulation pump assembly Electrical connections Hydraulic connections Filling and testing Balancing and adjustment of the system Double regulating lockshield adjustment Diagrams of manifold with double regulating lockshield Adjustment of flowmeter Adjustment of return balancing valve Balancing of the differential by pass kit Adjustment of the thermostatic mixing valve Tey ats Instruct ing Unit Operat ixing Floor M ions Instruct ing Unit Operat ixing Floor M Floor Mixing Unit Installation and Commissioning Instructions The floor mixing unit is a pre assembled manifold designed for underfloor heating systems with an integrated thermostatic mixing valve available from 2 to 12 ways It has a choice of either lockshield valves or flowmeters and is available with or without a pump High temperature circuits such as radiators or towel rails can also be added as shown using optional kits available from 2 12 ways with lockshield valves eo
6. kit Progress kit with bypass 1 2 terminal kit with bypass etc Note to install a 1 2 terminal kit c w bypass onto the right hand end of the manifold set unscrew and remove the drain fill valve from the end of the top rail and the manual air vent valve from the end of the bottom rail Fig D then install the kit by screwing the 1 2 M bridging t piece connectors onto the end of the manifold set Re With Grundfos 25 60 circulation pump installed with attach the drain fill valve and manual air vent valve onto control box positioned as shown in Fig E the 1 2 F connections available on the bridging t piece connectors For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions 2 Installation Circulation Pump Grundfos UPS 25 60 Progress ball valve kits with differential pressure by pass valve 1 1 2 BSPM Fig G Fig E Progress ball valve kits High temperature accessory kit Fig F Fig H 1 2 terminal kit with bybass for Floor Mixing Unit 95 Fig For more information please call us on 01993 824900 or view our website at www emmeti co uk oy aks Instruct ing Unit Operat ixing Floor M ions Instruct ing Unit Operat ixing
7. ng valve located on the low temperature return rail First check that return balancing valve component 7 on page 2 is completely open If it is not open by turning the nut under the cap using a 10mm socket Please make sure you compeletly open the balancing adjustment screw in the centre of the nut using a screwdriver We recommend filling each circuit separately opening the relative valves and double regulating valves each time and closing them again when the operation is completed The following commissioning instructions show separately the different procedures for setting up the designed flow rate using either lockshields or flowmeters For more information please call us on 01993 824900 or view our website at www emmeti co uk oy aks Instruct ing Unit Operat ixing Floor M ions Instruct ing Unit Operat ixing Floor M Floor Mixing Unit Installation and Commissioning Instructions 3 Balancing and Adjustment of the System 3 1 Double regulating lockshield adjustment Fig K Fig L Emmeti have evolved a new and superior lockshield design This allows easier quicker and more accurate onsite setting of the correct flow It is more accurate at maintaining the correct low flow when set to a small aperture This lockshield can be upgraded on site to become an integrated flow meter and lockshield How to balance using the lockshield Remove the red cover 1 The black
8. os 3 Kv 3 3 Pos 4 Kv 2 9 co OO eer S S ST A Pos 5 Kv 2 5 amp 0100 Pos MAX Kv 1 8 O 7 al 0 010 p thos gt lt 3 0 001 Q 0 000 100 1 000 10 000 c Q l h 5 Nominal conditions T 65 C T 15 C Pray Pem Knob positions Min 1 2 3 4 5 MAX o gt Temperature C 25 33 36 43 55 fas 1 4 Schematic System Diagram gt m e e LL KIA 1 K KA The numbers refer to item 1 1 on previous page For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions 2 Installation 2 1 Assembly Installation 2 2 Dimensional Data Floor Mixing Units can be wall mounted using the brackets provided with screws and plugs suitable for the mounting surface see Fig A Alternatively it can be mounted in Emmeti cabinets suitable for a depth of not less than 130mm see Fig D ions Instruct ing Slots for wall mounting or for insertion in Metalbox enclosure M 24x19 Unit Operat Minimum 300 mm ixing Fig A Floor M E iS Q S ej Fig B For proper selection of the Metalbox enclosure check overall clearances see figs C D E F G H I needed for the Floor Mixing Unit including circulation pump and any other accessories such as the high temperature accessory
9. our fingers adjust the flow using the black spanner flats 2 You can read the required flow in litres per minute directly from the red in dicator against the scale in the clear flow meter housing When you have achieved the desired flow rate raise the white sleeve 1 again until it is engaged against the black spanner flats 2 You can seal the white sleeve into position using wire and a lead seal or product code 01306320 red circuit indi cator bands see the end of this section or our Technical Product Guide section 5 Manifold Accessories If you are using lead and wire make use of the 2 holes in the white sleeve 3 For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions 3 Balancing and Adjustment of the System Cleaning the window Turn the white sleeve 1 clockwise until the outer sleeve isolating function is fully closed Remove the window housing by securing the black spanner flats 2 inner sleeve then using either hand pressure or a 17mm ring spanner gently unscrew the window housing anticlock wise Clean the window and screw it back on Turn the white sleeve 1 anticlockwise until the isolating facility is fully open again Flow rate measuring device pressure drops 300 250 200 150 100 50 60 120 18 24 300 300 Q h Ap mbar completel
10. ows on the upper disk red arrow to increase temperature blue arrow to decrease With the system at full operating capacity check the temperature reached using the temperature gauge on the flow manifold component 8 figure on page 2 and make any corrections using the knob to reach the required value Caution N B Heating of the floor system can occur only after curing of the slab minimum 28 days for cement slabs Before installing flooring it is necessary to start the system with a water temperature of 25 C to be maintained for 3 days Then increase by 5 C every 3 days until reaching a temperature of 50 C which is to be maintained for at least 4 days Temperature difference to change the AT of the low temperature floor system you can use the speed selector of the circulation pump and also the return balancing valve component 7 on page 2 To increase the AT reduce the operating speed of the circulation pump To decrease the AT increase the operating speed of the circulation pump and as necessary partially close the by pass valve see section 3 4 To determine the secondary return temperature it is advisable to install Tee thermometer holders M F 24x19 with corresponding temperature gauge on the connections M 24x19 of the return manifold or only for Floor Mixing Unit without high temperature 2 or 3 way accessory kit install the Progress kit with thermometer holder and temperature gauge Toyah Instruct
11. plastic assembly underneath has an inner sleeve and an outer sleeve The outer sleeve is used for isolating the valve actuated using the impression in the top of the red cover The inner sleeve is used to balance the circuit increasing or decreasing the flow by using a 4mm allen key placed in the hexagon recess in the centre The valve is supplied in the fully isolated position flow is closed First fully open the circuit Turn the red cover over and using the top turn the outer isolating sleeve 2 anticlockwise until the circuit is fully open rotate until you feel steady resistance then stop Then rotate back half a turn To verify you will have seen theblack plastic assembly rising Then using the 4mm allen key placed in the hexagon recess rotate the inner balancing sleeve 3 clockwise To verify you will have seen the inner sleeve falling Rotate until you feel a strong resistance then stop Rotate back half a turn The lockshield is now ready for flow setting NOTE Make sure you do not leave the inner balancing sleeve in the fully open posistion back it off half a turn to be sure the o ring is not stressed Using the graphs below 3 2 you can calculate the number of turns required to reach your chosen flow rate Now start to open the inner balancing sleeve anticlockwise by the number of turns you have calculated Then stop It is now set Replace the red cover To prevent tampering you can seal the red cover into po
12. sition using wire and a lead seal making use of the 2 holes in fins 4 on the red cover 3 2 Diagrams of manifold with double regulating lockshield Pressure drops electrothermic valve lockshield valve 1000 B10 amp 2 lt Kv 0 05 Kv 0 10 Kv 0 26 kv 0 45 Kv 0 72 Kv 0 98 Kv 1 07 10 valve fully open TA All open The above values refer to water temperature 15 C Ap pone way p return 9 no of turns for inner balancing sleeve Calculation methods How to calculate the Ap pressure drop with a 200 l h Q water delivery capacity determined by the valve and lockshield with 2 5 turns opening of the inner balancing sleeve 1 Method Use the pressure drop diagram Q 200 I h Ap 40 mbar where Kv stands for O delivery capacity in m h corresponding to Ap equalling 1 bar Kv Q VAp The relationship between bar Ap m h and Q de capacity is as follows Ap Q Kv 2 Method Use the Kv diagram Kv 0 98 Q 0 2 m h Ap 0 27 0 987 0 04 bar KV values at different openings electrothermic and lockshield valve 1 2 1 0 0 5 1 1 5 2 2 5 TA TA Fully open The values are obtained with a water temperature of 15 C valve fully open For more information please call us on 01993 824900 or view our website at www emmeti co uk 3 3 Adjustment of double regulating val
13. thermic heads can reach the wiring centre ideally on the lower face of the centre then fix the centre to the wall using the screws and plugs supplied Cabinet mounting where the Floor Mixing Unit is installed in a Metalbox manifold cabinet the wiring centre can be installed above or to one side of the manifold providing all electrothermic head cables can reach the centre Make the electrical connections to the centre as shown in the installation leaflet For more information please call us on 01993 824900 or view our website at www emmeti co uk 2 Installation 2 5 Hydraulic connections Connect the primary flow and return pipes and each of the individual circuits as shown in the example below Floor Mixing Unit Installation and Commissioning Instructions Manual Air Vents O Return balancing valve Primary flow Lockshields Primary return _ Drill Fill valves 2 6 Filling and testing The manifolds are provided with double regulating valves supplied fitted with either lockshields or flowmeters as standard and a return balancing valve in the closed position Open them before filling the system For filling use the adjustable drain fill valves with 3 4 connection located at the beginning of the low temperature flow rail and at the end of the low temperature return rail letting out the air contained inside the system by means of 2 manual air vent valves and the drain and filli
14. valve the shutter 4 the adjustment screw will stop the shutter TA is fully open Z when it reaches the set position All values are measured at a water temperature of 15 C im gt Screw the cap back 1 on Kv Values return balancing valve 3 5 hn o 3 t gt o Stop ring 25 LL 5 15 1 0 5 o m 0 1 2 3 4 5 6 7 8 9 no of opening turns of the valve adjustment screw Fig M For more information please call us on 01993 824900 or view our website at www emmeti co uk 3 5 Balancing of the differential by pass kit e Kit Progress c by pass calibrate the differential value based on the maximum pressure drop and the maximum flow rate established for high temperature e Kit Terminal c by pass calibrate the differential value based on the maximum pressure drop and the maximum flow rate established for low temperature 0 8 0 7 0 6 0 5 0 4 0 3 1 0 2 aia ee Cee 0 1 Ap bar 0 0 100 200 300 400 500 600 Q l h For more information please call us on 01993 824900 or view our website at www emmeti co uk Floor Mixing Unit Installation and Commissioning Instructions 3 Balancing and Adjustment of the System 3 6 Adjustment of the thermostatic mixing valve Adjust the temperature of the mixed water for the low temperature system by turning the thermostatic mixing valve knob component 6 on page 2 in the direction of the coloured arr
15. ve with built in flow rate measurement device if applicable Range of measurement 0 4 I min Maximum operating pressure 6 bars Max operating temperature 90 C Kv 0 15 1 I min 0 55 4 l min Kv max off scale 0 9 Precision 10 fs fs Bottom of scale How to balance the circuits using flowmeters The internal construction has an inner sleeve and an outer sleeve The outer sleeve 4 is used for isolating the valve actuated by raising the white sleeve 1 to engage The inner sleeve is used to set the flow in the circuit increasing or decreasing the flow by using the provided 19 mm spanner flats provided 2 The change in flow can be read in the scaled window The valve is supplied in the fully isolated position flow is closed First fully open the circuit as described below Lift the white sleeve 1 Turn the white sleeve anticlock wise This moves the outer isolating sleeve anticlock wise operating only the isolation function opening the circuit Continue until fully open To verify you should see the whole of the flow meter rotating and rising Stop when the resistance is strong You are now ready to use the flow setting function Then rotate back half a turn to reduce stress on the o ring stop Carry this out under flow conditions Lower the white sleeve 1 Using a 19mm spanner or y
16. with on off switch Code U9360020 EWC 1 24V 8 way wiring centre with on off switch This allows the connection of the mains power supply thermostats and actuators with electrical interlock terminals for the boiler and manifold pump as required by Building regulations Full instructions are provided with both items Please ensure that the electrical wiring of the installation and connections to and from electrical system components are in accordance with BS 7671 the latest edition of the IEE Wiring Regulations High limit thermostat code 28130632 Wall Mounting Install the high limit thermostat adjacent to the Floor Mixing Unit where the thermostat phial can be trapped between the rubber mounting pad in the support bracket and the surface of the flow manifold fixing it to the wall with screws and plugs Cabinet mounting Where the Floor Mixing Unit is installed in a Metalbox manifold cabinet install the thermostat in the enclosure above or to the side of the manifold assembly as shown in Fig M Make the electrical connections to the thermostat as shown in the installation leaflet Maximum suggested thermostat setting 45 50 C for cement slabs for other materials refer to the maximum values as stated by the supplier and not more than 55 C EN 1264 4 EWC 1 wiring centre codes U9360010 U9360020 Wall mounting Install the wiring centre adjacent to the Floor Mixing Unit so that the electrical cables from the electro
17. y open oy aks Instruct ing Unit Operat ixing Floor M Floor Mixing Unit Installation and Commissioning Instructions 3 Balancing and Adjustment of the System 3 4 Adjustment of return balancing valve c e function of this valve is to adjust the total flow o ressure Drops return balancing ro The f i f this valve i dj h I fl f P D return balancing D water through the manifold When it is fully shut no S water can pass through the valve into the primary return 1090 Tez P Kv 0 13 2 In order to ensure that the mixing valve operates ei les D correctly within its temperature setting range the valve 5 Dkv 151 f must be at least partially open The position of the valve 5 a A A ERE V e should be determined by using the tables shown at right 8 Dkv 3 23 Adjust as follows TA Kv 3 44 Unscrew and take off the cap 1 E 100 Using a 10mm socket screw in the valve clockwise until oO it is fully closed 2 Q Use a screwdriver to screw in the adjustment screw completely until it stops 3 The valve is now ready for setting im f am Unscrew the adjustment screw 3 by the desired number 1 1000 mD of turns using the screwdriver Flow rate It h rep Open the valve 2 using the socket key in order to raise Curves 2 7 indicate the number of turns open of the
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