Beruflich Dokumente
Kultur Dokumente
JUNE 2012
CONTENTS
How to use this guide ............................................................................................................03
INTRODUCTION
About Polypipe Underfloor Heating........................................................................................04
An overview of Polypipe Underfloor Heating Systems .............................................................06
Selecting the right Polypipe Underfloor Heating System .........................................................07
System selection ....................................................................................................................08
Design service ........................................................................................................................09
Polypipe Registered Installer Network .....................................................................................10
What you can expect from your installer ................................................................................11
Guide to floor coverings for underfloor heating systems.........................................................12
INSTALLING THE SYSTEM
Solid Floor..............................................................................................................................14
Floating Floor .........................................................................................................................18
Suspended Floor ....................................................................................................................20
Modular Heating Panels (MHP)...............................................................................................24
Overlay...............................................................................................................................30
Overlay Lite ........................................................................................................................38
CONNECTING & CONTROLLING THE SYSTEM
Connecting to heat source .....................................................................................................40
Manifolds ..............................................................................................................................41
Water temperature controls ...................................................................................................42
Room temperature controls ...................................................................................................44
Single room applications ........................................................................................................50
System commissioning ...........................................................................................................52
TECHNICAL DATA
Heat output tables .................................................................................................................54
General system information ...................................................................................................55
FAULT FINDING CHARTS
Hydraulic fault finding chart ...................................................................................................56
Electrical fault finding chart (master connecting box)..............................................................57
STANDARDS
Accreditations, standards and guarantees ..............................................................................58
FORMS
Design enquiry form ..............................................................................................................59
Polypipe Underfloor 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 manufacturers 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.
02
Important notice:
This publication is provided as a comprehensive guide on how to install Polypipe
Underfloor 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.
Technical data
Towards the back of this guide you will find technical data such
as heat output tables, pipe data and general system information
as well as useful forms to use with our Product Selectors 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 benefits, you can
find useful case studies and details of Polypipe stockists.
Video instructions on underfloor heating installation are
also available to view.
For Polypipe Registered Installers we have created a dedicated
members area on our consumer site, www.freeyourwalls.com.
Here you can access full marketing resources, update your web
profile and see great promotional offers from our network partners.
03
04
Easy installation
Flexible approach
Maintenance free
Once installed, a Polypipe Underfloor Heating System is virtually
maintenance free. There are no joints in the pipe work within the
flooring, significantly reducing the possibility of leaks. Polypipe
Underfloor Heating products are subjected to rigorous testing
and meet a number of exacting standards, full details of which
can be found on page 58. All our manufacturing processes are
monitored and controlled in accordance with the international
quality standard BS EN ISO 9002.
Choosing underfloor 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 confidence in product performance,
and providing our customers with peace of mind, Polypipe
Underfloor 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.
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:
U Pre-project training at one of our training centres
U Pre-project training by distance learning
U On-site assistance
We also provide an extensive back up service:
U Technical representation available to discuss systems
in general and particular projects
U www.ufch.com
U vii>V
U Technical Installation CD
U Specialist Technical Hotline on 01709 770000
Energy efficient
Underfloor 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 efficient with higher temperature heat
sources, for example solar and solid fuel, where the correct water
temperature can be set at the point of distribution.
05
AN OVERVIEW OF POLYPIPE
UNDERFLOOR HEATING SYSTEMS
Polypipe has the widest available range of underfloor heating systems, with a
product available for every conceivable floor type or residential heating project.
With Polypipe, underfloor heating is not restricted to new build developments or
self build projects. Our unique Overlay system 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 underfloor heating into upper floors.
The notes below provide a brief overview of the methodologies
employed to install underfloor heating systems for various floor
types. Refer to the overview on the page opposite. Full installation
instructions for each floor type can be found in the section titled
Installing the system on pages 14 to 39.
Solid Floor
Polypipe Underfloor Heating can be permanently built into solid
concrete or screeded floors. As required by current Building
Regulations, insulation is built into the floor directly beneath the
unique Polypipe lightweight plastic floor panel. The heating pipe
is simply slotted into the panel and then permanently covered by
the screed. Suitable for all floor coverings, solid floor systems can
incorporate 15mm or 18mm pipe.
The floor 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 floor 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 floor
screed is required by Building Regulations. Edge insulation also
acts as an expansion joint.
Floating Floor
When installed in floating floors, Polyplumb pipe is simply pressed
in to the pre-formed heat spreader plate, which sits in grooves
within the floating floor insulation panel. The floating floor
system is then covered with 18mm chipboard sheeting.
Suitable for all floor coverings, floating floor systems can
incorporate 15mm or 18mm pipe.
06
Suspended Floor
For installations in suspended floors, Polypipe Underfloor Heating
uses double heat spreader plates. Alternatively, pipes can be laid
on top of insulation between joists. Standard tongue and groove
floorboards are laid on top of the system. Suspended double heat
spreader plate systems use 15mm pipe.
Overlay
Overlay allows underfloor heating to be installed into existing
spaces quickly, easily and practically. This unique system is
supplied with a choice of patented low profile panels to suit
all types of floor coverings. Overlay is laid over existing solid
or timber floors.
Existing floor
Underfloor
SOLID
FLOOR
All floor
coverings
High mass
system
Typical ground
floor or beam
and block
construction
FLOATING
FLOOR
Over floor
SUSPENDED
FLOOR
All floor
coverings
except natural
wood / thick
laminates
OVERLAY
LITE
OVERLAY
Lightweight
floor coverings
Tiles or
natural wood
Larger areas
Wet areas
Multiple rooms
Lightweight
construction
No wet trades
required
SUSPENDED
FLOOR
MODULAR
HEATING
PANELS
All floor
coverings
All floor
coverings
Fit from
above / below
Traditional
joists
Traditional
heat source
Traditional
or engineered
joists
Traditional or
renewable heat
sources
07
SYSTEM SELECTION
PRODUCT SELECTOR
for UFCH & OVERLAY
Polypipe has removed the mystique from specifying the correct underfloor
heating solution for a given project and the need to calculate all of the individual
components required. Our unique
Product Selector, which is available
online at www.ufch.com and also at www.freeyourwalls.com, uses a simple 3 step
process to calculate your requirements using basic project data that you provide.
The system includes a range of over 150 pre-configured systems that contain all
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.
PRODUCT SELECTOR
for UFCH & OVERLAY
Room packs
Room packs are designed for single room applications: i.e. kitchens,
bathrooms, conservatories, loft conversions and extensions.
This range of underfloor heating packs contain all the flooring
and control equipment required for a single project, in solid floor,
our traditional Overlay and our NEW Overlay Lite systems.
All room packs have a maximum heat output of 100W/m2.
House packs
House packs provide you with a quick and easy way to select
and order from our range of underfloor heating products,
without the need to submit a design. The packs are designed for
solid, floating or suspended (double heat spreader plate) systems,
OverlayTM and OverlayTM Lite projects.
Packs can be applied to all new build or renovation properties
that fall into the following criteria:
U ,i}72
U 72 - Solid 200mm centres, floating and suspended floors
100 W/m2 - Solid 100mm centres, OverlayTM and OverlayTM
Lite floors
U *iiLVi `},i}>
08
Design services
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 59, or at www.ufch.com, and submit your drawings
to Polypipe. You will then receive a complete design and
component list for the project.
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 59, or at www.ufch.com, and submit
your drawings to Polypipe. You will then receive a complete design and
component list for the project.
Installation service
U *iiV>}>>}Vii
U *iiV>}L`>Vii>}
U "i>>Vivii``}iV>>
Backup service
U /iVV>iii>>>>Li`Vi
in general and particular projects
U 7iLi>`v>
U -iV>/iVV>i01709 770000
09
POLYPIPE REGISTERED
INSTALLER NETWORK
Finding a Polypipe
Registered Installer
Finding a member of the Polypipe Registered Installer Network
couldnt be easier. Simply visit www.freeyourwalls.com and
locate the stockist finder quick link at the bottom left hand corner
of the home page.
Enter your postcode, select Installer and click on the Find button
(installers can also use this function by selecting Stockist to search
for local stocking merchants).
10
Once you have selected one or more installers you can email them
directly from the website or use the displayed contact details to
get in touch by phone.
Polypipe Registered Installers are vetted based on their experience and expertise
in installing Polypipe Underfloor Heating Systems. Your contract is directly with
the installer, and we cannot provide any guarantee in respect of their work.
We do, however, provide extensive warranties on our products. In the unlikely
event that you experience a problem with any aspect of your experience with
a Polypipe Registered Installer you should notify us on 01709 770000.
All Polypipe Registered Installers are provided with a personalised certificate to prove their
authenticity. You should be shown this but if not, please ask to see it.
11
Underfloor 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.
12
Vinyl
Timber
Laminate
13
SOLID FLOOR
U
U
U
U
14
Pre-installation requirements
The sub floor must be swept clean and be free from mortar residues.
Step 3:
The floor panels are laid over the pre-installed insulation
Approx. 100W/m
50C
100m (15mm pipe)
120m (18mm pipe)
12m2 at 100mm centres
22m2 at 200mm centres
30m2 at 300mm centres*
*(18mm pipe only)
2
Installation
Fitting insulation
Step 1:
Pipes around this area should be secured using pipe clips which can
to ensure that any downward heat loss does not exceed 10W/m ,
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
Step 2:
Using edge insulation strip allows the free expansion of the floor
screed. The insulation strip should be installed around all perimeter
walls and fixed 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 floor plates
to the floor insulation. Edge insulation strip should be fitted in
addition to perimeter insulation required by Building Regulations.
underfloor heating system and cause the panels to rise up. Similarly
the panels should be firmly 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 floor panels the pipe
can be fitted 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).
15
90
180
Step 6:
Circuits being laid at 100mm or 200mm centres must be laid in a spiral
configuration. The first 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 first loop of pipe for 100mm
centres or 400mm from the first 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).
Conduit pipe
A 400mm length of conduit pipe should be fitted over the underfloor
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 floor 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 fitted around the
heating pipe where the pipe passes through the edge insulation strip,
e.g. room to room, or through expansion joints within the floor.
Conduit pipe should also be used where the pipe leaves the floor
adjacent to the manifold. This can be threaded down the pipe
after the pipework has been installed.
Step 8:
Now work back out from the centre by filling the space between the
inwardly spiralling loop of the primary circuit ensuring the pipe is laid
at the correct spacing centres.
16
Pipe
Conduit
Insulation
Sub floor
Finishing
Expansion joint
BS EN 1264-4 recommends that an expansion joint is constructed
in stone and ceramic finished screeds for every 40m2 of floor area
at a maximum length of 8m and an aspect ratio of 2:1.
Timber floors
Many people are concerned by the effect of heat on a timber
floor, but this concern is misplaced. The important factor is
the floor moisture content.
as corridors, etc.
The floor will re-absorb some moisture when the heating is not
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 fitting the solid oak covering (see diagram below).
Screed
Timber floor covering
Solid floor plate
Joist at 1m spacings
17
FLOATING FLOOR
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 floor structure as
required under current Building Regulations. However, care
should be taken when installing floating floor panels on top
of a primary insulation layer to ensure that excessive deflection
does not occur in the final floor construction.
18
Pre-installation requirements
The sub floor must be swept clean and be free from mortar residues.
Approx. 70W/m2
60C
80m (15mm pipe)
100m (18mm pipe)
25.8m2 at 300mm centres
(15mm pipe)
30m2 at 300mm centres
(18mm pipe)
Installation
Laying the floating floor panels
Step 1:
Lay the 1200 x 1200 x 50mm floating floor panels directly over
the entire floor area to be heated, ensuring the panel grooves are
aligned. The panels can be cut to fit where necessary.
Polyplumb
barrier pipe
Single heat
spreader plate
Insulated floating
floor panel
Finishing
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 floating floor panels.
These plates ensure an even spread of heat across the floor area
and hold the pipe firmly within place in the floating floor panel.
The room can then be finished by fitting 18mm or 22mm tongue and
groove sheets of chipboard, glued on the edge, over the floating floor
system. Mark the position of the pipe where door thresholds or carpet
strip are to be installed.
When laying a ceramic or stone floor covering ensure that any
deflection in the floor is minimised. It is recommended that a slip mat
or uncoupling membrane is used rather than a second layer of wood.
19
SUSPENDED FLOOR
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 fixed 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 centres.
450mm
1000mm
20
250mm
Pre-installation requirements
Key design and installation information
Approx. 70W/m2
60C
80m (15mm pipe)
17m2 at 225mm average
centres
Pipe
Double heat
spreader plates
4.5m/m2
2 plates/m2
Installation
The spreader plates can then be fixed evenly across the joists
and in accordance with your installation design.
Laying the pipe
Step 3:
Once the spreader plates have been fixed in place the pipe can
be fitted in to the grooves in a meander pattern. It is recommended
that the flow pipe from the manifold be taken to the furthest point
of the room when installing the circuit as this ensures that sufficient
heat is provided around the perimeters of the room.
Fitting insulation
Step 1:
Return
Flow
Double heat
spreader plate
Pipe
Joists notched to
accept pipe returns
Ceiling
Polyplumb
barrier pipe
Polystyrene
or foam insulation
Supporting joists
21
Finishing
Laying a timber floor covering
Step 5:
Battern systems
Trim the ends of the batten back to the last joist at alternative ends.
Correct application
Incorrect application
Step 4:
Lay pipe into the spreader plates in accordance with the installation
instructions on the previous page, ensuring you follow the
testing procedure.
Polyplumb
barrier pipe
Double heat
spreader plate
75mm x 25mm
battens at
450mm centres
22
Joists at spacing
greater than 450mm
or less than 350mm
Polyplumb
barrier pipe
Pipe clip
Joists at spacing
greater than
450mm or less
than 350mm
23
A new concept
in underfloor heating
Modular Heating Panels* are an exciting new product concept from Polypipe
that enable quick and simple installation of underfloor heating into suspended
floors in both new build and renovation projects.
Installing underfloor heating into upper floors can be
challenging, even in new build projects. Most conventional
underfloor heating systems comprise a single section of pipe,
housed or placed within another part of the system structure,
such as floor panels, which are cut to size on site. This works
fine as there are no interruptions to the laying of the pipe.
In suspended floor installations however, the pipe, plates and
insulation have to fit within an obvious obstruction:
the supporting floor joists. It is working around the joists,
and avoiding other services, that has often led to underfloor
heating being avoided in upper floors.
*Patent pending.
24
Product options
MHP is available in 6 panel sizes comprising 2 lengths and 3 widths:
MHP available lengths: 1.3m and 2.0m
MHP available widths:
25
Arrangement
Span
1 x 1.3m Panel
1.4m to 2.2m
1 x 2.0m Panel
2.2m to 2.8m
2 x 1.3m Panels
2.8m to 3.5m
1 x 1.3m Panel +
1 x 2.0m Panel
3.5m to 4.2m
2 x 2.0m Panels
4.2m to 5.0m
26
27
Pre-installation requirements
Planning
Before installing MHP panels ensure you have planned out the
When installing MHP panels from below you will need to mark
Once you have checked the marked out positioning, the MHP
or floors in place.
Installation
Finishing
Once you have connected your system up to the manifold and
tested it you can then finish the room by fitting the floor 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 20C to
18 bar pressure. Any installations once connected to the manifold
have a maximum test pressure of 6 bar.
28
Panel layouts
1 Panel layout
2 Panel layout
6
Product information
Heat output
Product
Code
No of panels
per pack
MHP49020
MHP49013
MHP38020
Flow
temp (C)
Av. floor
temp (C)
40
25.0
63
42
49
33
42
29
MHP38013
45
25.8
75
50
58
39
50
34
MHP33020
50
26.6
86
58
67
45
58
39
MHP33013
55
28.9
120
80
93
62
80
53
60
30.8
147
99
114
77
98
66
= 80% coverage
= 60% coverage
29
TM
OVERLAY
Underfloor heating
that fits over
existing floors
30
Installed over the existing floor and only 18mm in depth, Overlay allows
underfloor heating to be installed where traditional underfloor systems would
either require expensive excavation or would require the floor 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 floor coverings.
Overlay floor panel is a fibrous panel used for heavyweight floor coverings
such as ceramics, or where the floor 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 floor 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 underfloor heating solutions and are therefore ideal for both traditional
heating systems and low temperature renewable systems.
31
End return
Suitable for:
tiles, hard wood,
carpet or vinyl**
Cover board
12mm pipe circuit
18mm floor panel
600mm x 800mm
Overlay
floor panel
TM
Overlay
Choosing
your Overlay
floor panel
Floor finish
Cover detail*
Ceramic tiles
32
OverlayTM
Direct
Direct
or
Vinyl** - with cover layer
Fixing method
Cover board thickness indicated are minimum. The maximum thickness of any cover
board is 18mm. Sheet products other than those shown may also be suitable.
End return
Engineered wood,
laminate or carpet
Cover board
Heat diffusion foil
12mm pipe circuit
18mm floor panel
600mm x 1244mm
Overlay Lite
floor panel
TM
Overlay Lite
Fits over concrete
or floorboards
Overlay Lite is the ideal solution for laminate and engineered wood
floors which should be laid directly over the system.
Overlay Lite products are easy to install making it ideal for larger
floor areas.
Floor finish
OverlayTM Lite
Cover detail*
Engineered wood
Laminate
Carpet - with cover layer
Fixing method
Direct
Direct
10mm Ply / 6mm MDF
Approx. 100W/m2
45 to 50C
80m
12m2
Coverage 0.48m2
Coverage 0.75m2
Pipe
7m length/m2
End returns
Cover board thickness indicated are minimum. The maximum thickness of any cover
board is 18mm. Sheet products other than those shown may also be suitable.
33
Pre-installation requirements
Planning
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
End return
with panel
removed
End return
End return
with panel
removed
End return
34
35
Overlay
for heavyweight floor coverings
Installation
Laying end returns
Step 1:
Start by fixing two end returns to the floor in a corner of the room.
Remove the pipe panel if not required as per your floor plan.
This should be done by using suitable screws in the screw holes
of the end return panels when fixing to a wood floor, or by using
Overlay adhesive (code PB777) to bond the end returns
to solid floors.
Return bends with pipe
plate removed
First panel
Room wall
Return bends
with pipe plate
remaining
First row
Subsequent row
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.
36
Step 3:
When you get close to end of the first row fit two end returns
against the wall as in step 1 and if necessary cut an Overlay floor
panel to fit and complete the first 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.
Finishing
Step 4:
Once you have completed the first 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.
Using a floor filler/grout fill any gaps and voids, and fill around
any pipework.
Tiles can be laid directly on to the Overlay floor panels
or a cover board can be fitted prior to tiling.
When tiling directly over Overlay floor panels, use a sealant
with flexible adhesive and grout.
If fitting solid wood floors they can be discretely screwed through
the tongue and groove directly into the Overlay floor panel,
avoiding pipe circuitry, to minimise movement in the floor covering.
Example showing 10mm plywood cover
37
Overlay Lite
for lightweight floor coverings
Installation
Lay the panel ensuring you line up the grooves in the panel with
those in the end returns, then continue to lay the first row of panels
Step 1:
Start by fixing two end returns to the floor in a corner of the room.
Remove the pipe panel if not required as per your floor plan.
This should be done by using suitable screws in the screw holes
of the end return panels when fixing to a wood floor or by using
Overlay adhesive (code PB777) to bond the end returns to
solid floors.
Return bends with pipe
plate removed
Step 3:
When you get close to end of the first row fit two end returns
against the wall as in step 1 and if necessary cut an Overlay
Lite floor panel to fit and complete the first row.
First panel
Room wall
Return bends
with pipe plate
remaining
First row
38
Subsequent row
Step 4:
Once you have completed the first row begin the process again with
Step 7:
Starting from your manifold position and, allowing enough pipe for
connections, lay the pipe into the grooves of the Overlay Lite floor
panel in accordance with your plan.
Step 5:
Use the self adhesive foil tape along the long panel joints to securely
fix the panels to the adjacent row.
Step 8:
Once you have finished 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.
Step 6:
Now continue this process, completing the whole room.
Finishing
Laminate and engineered wood can be laid directly over Overlay
Lite floor panels. Where carpet is being fitted, first fix a 6mm MDF
or 10mm plywood using a contact adhesive, then continue to lay the
floor covering as normal. It is advisable to mark out pipe positioning
to avoid stapling pipes when fitting carpets.
39
Heat pumps
Polypipe Underfloor 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 sufficient system flow
rate for the underfloor heating installation, it is recommended
to fit the manual blending valve and pump pack as supplied
by Polypipe Building Products Ltd.
40
MANIFOLDS
Manifolds are common to all systems above 30m2, independent of the underfloor 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 flow and the top manifold is the
return. Each manifold port comes complete with a Polyplumb
push fit connection. Pipes are connected to manifolds by
inserting a pipe stiffener into the pipe and simply push fitting
the pipe into the port.
The flow meter on each flow port of the manifold provides
a visual indication of the flow 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.
62
80
50
Outlets
L (mm)
2
190
3
245
4
300
5
355
6
410
7
465
Remove the manifold from the box and arrange the flow 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.
Outlets
L (mm)
9
575
10
630
11
685
12
740
13
795
14
850
Dimension
A (mm)
B (mm)
C (mm)
8
520
1
39
64
86
B
C
41
42
155mm
110mm
50mm
30mm
Manifold bend installed with underfloor heating control pack can also be used with Alpha UFH control pack.
130mm
40mm
43
44
Room
thermostat
room 2
satisfied
Boiler
on
Zone
valve open
UFH Pump
on
Actuator
room 1
open
Actuator
room 2
closed
Circuit
room 1 open
Circuit
room 2 closed
Building regulations
requirements
U }iii>`i}iii}>i>
U -iL>V}>>LiV>iiVi`i`ii`
as a minimum.
NOTE: this applies to installations connected to both domestic
gas boilers and heat pumps
U
>V`Li`i`i>
programmable thermostat. Where 2 rooms have a similar
function e.g. kitchen and utility room It may be possible to
use one thermostat to control both rooms
Control type
Time control
Per room
Display / operation
Per manifold
Digital
Programmable
Wired Thermostats
Programmable
RF Thermostats
Dial
Connectivity
Wired
Wireless RF
Digital Wired
Thermostats
Digital RF
Thermostats
Dial Wired
Thermostats
Dial RF
Thermostats
45
Control equipment
- Room Thermostats
sensor connection.
U {i{>v`Vi,* {
/
,i
U iV
U `>>`L`i
Digital Room Thermostats (PBDIG)
U ii}>vi>}>}
U -ii`iwi`}>}
U i>v>ViV
46
Wiring centres
Ancillary items
U *}ViVi>iviiV
These units are always used in conjunction with the master unit
and provide simple wiring of actuators and room thermostats for
multiple zone control. Neon indicators show room activation.
47
230v
Supply
L N E
E N L
OR
RF Clock
PB4CTC RF
NC
End Switch
2 Port Zone Valve
RF Receiver
230v
Supply
L N
Note:
Only use this
connection when
using a Single
Room Thermostat.
If using Slave do
NOT use.
Power Supply
L N
C 1
Remove Link if
Zone Valve Fitted
Clock
C 1
RF Receiver
OR
Volt Free
Contact
Boiler
230v S/L
Connection
Boiler
UFH Pump
Time Clock
Not fitted when using
programmable stats
Hard Wired
Room Stat Options
PBPRP
PBDIG
PBRS
230v
Supply
2 Wire Actuators
PB00401, Max
4 per zone
48
Remove Link if
Time Clock Fitted
Remove Link if
Zone Valve Fitted
OK
L N E
230VAC
Power Supply
PB2CTC 2 Channel
Hard Wired Time
Clock option
Pump
Zone 1
230V AC
Boiler Connection
L N E
2 Wire Actuators
PB00401, Max
4 per zone
Zone 2
Volt Free
Boiler Connection
OK
2 Wire Actuators
PB00401, Max
4 per zone
49
200mm
Thermostatic
blending valve
Pipe
thermostat
260mm
Pump
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.
Pump speed
control
Heating
return
Tees and spigot
elbows for
second circuit
if required
Heating
flow
Underfloor
heating flow
Underfloor
heating return
Connection
from nearest
radiator
The diagram above shows the ZRU connected to operate with the
boiler on / off firing. 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 floor installations may require the
timings of the existing heating to be altered to allow the
underfloor 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 / underfloor
heating independently
Programmable room thermostat
Zone
valve to
underfloor
heating
Zone valve
to radiator, etc
50
Connection
from main
distribution
pipe work
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 fire the boiler.
Installation of ZRU
Step 1:
Remove the underfloor heating return pipe from ZRU and blank
off the ZRU underfloor heating return port with a short pipe
with a blank end or a blanking plug.
Filling the ZRU
Step 2:
Step 1:
Step 3:
Step 2:
Step 3:
Step 6:
Vent the ZRU through the air vent and pump vent.
Wiring details
IMPORTANT NOTE: If in any doubt you should contact
a qualified electrician.
The water temperature must be 45C to operate the unit.
Wiring diagram
Room stat (example) - not supplied
Blank off
underfloor
heating
return to ZRU
Open
underfloor
heating
flow isolation
valve
Vent underfloor
heating system from
underfloor heating
return pipe
Remove
link if
using a
room
thermostat
PRODUCT SELECTOR
Room packs
Solid Floor
Overlay
Overlay Lite
Area
12m2 (So12Z)
12m2 (O12Z)
12m2 (OL12Z)
20m (So20Z)
20m (O20Z)
20m2 (OL20Z)
30m2 (So30Z)
30m2 (O30Z)
30m2 (OL30Z)
Pump
51
SYSTEM COMMISSIONING
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 sufficient heat input and flow rates are being
provided at the manifold(s).
2
Manifold
flow meter
Close the manifold isolating valves (1) & (2). Connect a hosepipe
to manifold return drain off point (4) and take to a drain.
Connect a second hose pipe to the manifold filling point (3) and
attach to mains cold water supply (3 bar max). The connections
to the manifold drain and fill points are BSP. Use flexible
tap connectors for the simplest method of connection.
Close all of the flow adjusting valves on the return manifold rail
by turning the blue caps in a clockwise direction. Open all of
the manifold flow meters on the manifold flow rail by turning
them in an anti-clockwise direction using a radiator vent key.
Open the first circuit on the manifold by turning the blue cap
anti-clockwise and then open the drain and fill points (4) & (3).
Using the mains cold water supply flush out and fill the
first circuit. Once this circuit is running clear and free from air,
open the second circuit on the manifold and repeat the process
until all of the circuits are fully opened and purged of air.
Close the drain and fill points.
IMPORTANT NOTE: All of the manifold flow meters must be
fully opened prior to flushing and filling the manifold circuits.
52
Remove the blue cap from the manifold flow port and,
using the bleed key provided, turn the flow adjustment spindle
clockwise to completely close the circuit.
53
TECHNICAL DATA
Solid floor
Mean water
temperature C
Pipe
spacing mm
Output
W/m2
Surface floor
temperature C
Pipe
spacing mm
40
150
150
68.0
26.3
79.0
28.1
55
150
101.0
30.1
60
150
124.0
32.0
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
Mean water
temperature C
Pipe
spacing mm
50
300*
64.3
26.0
40
90
55
300*
66.7
26.9
40
225/300
Output
W/m2
31.7
Surface floor
temperature C
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
25.8
150
60.9
Pipe
spacing mm
61.0
Surface floor
temperature C
45
100
Mean water
temperature C
Output
W/m2
50
40
54
Mean water
temperature C
Output
W/m2
52.0
Surface floor
temperature C
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
TECHNICAL DATA
Maintenance
Strength
The Polyplumb system is suitable for use in working applications
up to 12 bar / 20C (6 bar / 90C). Pipes are suitable for bending
to a radius of 12 x diameter when unsupported or 8 x diameter
when supported.
Connections and fittings 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 fittings are tested to BS 7291: Parts 1 and 2,
which incorporates a pressurised thermal cycling test and a test
regime at temperatures of 114C 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 underfloor heating
systems, we recommend barrier pipe is used throughout to
minimise the potential for oxygen ingress into the system.
Light
Polyplumb pipe and fittings 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-efficient of thermal expansion of Polypipe polybutylene
pipe is 1.3 x 10-4m/mC. It accommodates expansion by its
modulus of elasticity.
Water
The polybutylene material used in Polyplumb pipes and fittings 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 flexibility 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 affixing
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 fittings.
Compatibility
Polypipe polybutylene pipe connects to rigid pipe systems
and is compatible with all recommended inhibitors.
For details of compatibility with specific building materials,
such as filler foam and wood worm treatments, please consult
the Polypipe Technical Hotline on 01709 770000.
Polypipe pipes and fittings can be painted using emulsion or
undercoat and gloss. Cellulose based paints, strippers or thinners
must not be used.
Durability
Polypipe Underfloor 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 or www.freeyourwalls.com to a
view a full copy of our current guarantee(s).
55
Boiler fault
NO
Electrical fault
(see electrical fault
finding guide)
START
Is the boiler firing
and the primary
pump operating?
NO
NO
Check if the
underfloor heating
zone valve is open
YES
Is there hot water
present prior to
underfloor heating
mixing valve?
YES
NO
YES
NO
YES
Check temperature
adjustment on
underfloor heating
mixing valve
NO
Electrical fault
(see electrical fault
finding guide)
YES
YES
NO
YES
Fault finding
complete
56
NO
YES
Pump fault
Check if the
actuators are open
NO
Check 230V
signal to actuator
from slave unit
NO
Electrical fault
(see electrical
fault finding
YES
Actuator fault
YES
YES
Is the system
performing
correctly?
Underfloor
heating pump
operating
NO
START
NO
NO
NO
NO
NO
NO
NO
YES
YES
Is there 230V at
L terminal on PCB?
YES
Is Green Power
LED illuminated?
YES
Is 230V present on
all T2 terminals?
YES
Is 230V present on
all T1 terminals?
YES
Are the zone valve
and underfloor heating
pump operating?
YES
Is there 230V to NC Boiler
switch live connection?
(Check operation
of Volt free relay
connections if using 24V)
YES
Check boiler connection
NO
57
Accreditations, standards
and guarantees
One of Europes largest manufacturers of plastic plumbing and
heating products, Polypipe Building Products Ltd has developed
a unique range of underfloor heating solutions. Designed
for installation in to both existing and new build projects all
Polypipe products are manufactured and tested to the 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
FM00318
Installation standard
Guarantee
British standard
58
Client:
Address:
Telephone:
Post Code:
Mobile:
SENDERS DETAILS
Client:
Contact:
Address:
Post Code:
Telephone:
Designs to be returned to
Client
Mobile:
Sender
Manifold Position(s)
Ground Floor
1st Floor
2nd Floor
NOTES
CONSTRUCTION DETAILS If NOT to current Building Regulations
U Value
(W/m2 deg C)
External Walls
Roof
Windows
59