REHAU Easy Heat Installation Manual September 2014

Building SolutionsAutomotive

Industry

www.rehau.co.uk/easyheatValid from August 2014Subject to Technical Alterations

REHAU EAsy HEAt tEcHnicAl And instAllAtion mAnUAl

ENERGYEFFICIENCY

contEnts

1 . . . . . . . . Information and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . . . . REHAU Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 . . . . . . . . Introduction to REHAU Easy Heat . . . . . . . . . . . . . . . . . . . . 73.1. . . . . . . System architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1.1 . . . . . Traditional domestic heating systems . . . . . . . . . . . . . . . . . . . 73.1.2 . . . . . REHAU Easy Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2. . . . . . . REHAU Easy Heat components . . . . . . . . . . . . . . . . . . . . . . . . 83.2.1 . . . . . REHAU RAUTHERM universal pipe . . . . . . . . . . . . . . . . . . . . . 83.2.2 . . . . . Floor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2.2.1. . . . REHAU Easy Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2.2.2. . . . REHAU RAUFIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2.2.3. . . . REHAU Tacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2.3 . . . . . Controls systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2.4 . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 . . . . . . . . Transport and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1. . . . . . . Handling the pipes and system components . . . . . . . . . . . . . 154.2 . . . . . . . .Handling and storage of REHAU Easy Panels and REHAU plywood . 15

5 . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.1. . . . . . . REHAU Easy Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.1.1 . . . . . . Categories for residential, social, commercial and administration . 16

area including additional sub categories for the UK5.1.2 . . . . . Conditioning of REHAU Easy Panels . . . . . . . . . . . . . . . . . . . 175.1.3 . . . . . Installation of REHAU Easy Panels. . . . . . . . . . . . . . . . . . . . . 175.2. . . . . . . Primary flow and return including flow controls . . . . . . . . . . . 185.2.1 . . . . . System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2.2 . . . . . Flow and return pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2.3 . . . . . Mixing components for flow temperature (if required). . . . . . . 185.3.4 . . . . . REHAU zone valve and wiring for NEA HT . . . . . . . . . . . . . . . 185.3. . . . . . . REHAU Easy Control with fixing bracket. . . . . . . . . . . . . . . . . 19 5.4. . . . . . . Laying UFH pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.4.1 . . . . . REHAU Easy Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.4.2 . . . . . REHAU RAUFIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5.4.3 . . . . . REHAU Tacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.5. . . . . . . REHAU plywood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.6. . . . . . . REHAU wall thermostats/remote sensors. . . . . . . . . . . . . . . . 265.6.1 . . . . . REHAU wall thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.6.2 . . . . . REHAU remote sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5.6.3 . . . . . REHAU wall access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.6.4 . . . . . REHAU NEA HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 . . . . . . . . Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.1. . . . . . . Fill and flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.1.1 . . . . . No primary pipework installed . . . . . . . . . . . . . . . . . . . . . . . 316.2. . . . . . . Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.2.1 . . . . . General guidelines for pressure testing . . . . . . . . . . . . . . . . . 316.2.2 . . . . . Pressure testing the floor heating systems with water . . . . . . 326.2.3 . . . . . Pressure test certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.3. . . . . . . System balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.4. . . . . . . Programming NEA HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.4.1 . . . . . Thermostat control and display. . . . . . . . . . . . . . . . . . . . . . . 356.4.2 . . . . . Adjusting set temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 356.4.3 . . . . . Operational modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.4.4 . . . . . Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366.4.5 . . . . . General function information . . . . . . . . . . . . . . . . . . . . . . . . 366.5.6 . . . . . Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7 . . . . . . . . Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.1. . . . . . . Design factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.2. . . . . . . Typical outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.3. . . . . . . Laying patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.3.1 . . . . . Reverse spiral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.3.2 . . . . . Double meander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.3.3 . . . . . Single meander. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8 . . . . . . . . Standards and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 39

2

ovERviEw of REHAU EAsy HEAt

An underfloor heating system providing Comfort, Control and Confidence featuring:

REHAU Easy Panel

REHAU Easy Panel replaces your current structural chipboard deck for all joist spacings up to and including 600mm. This is unique to REHAU.

- Independently tested by TRADA for fire rating and structural integrity, covering all domestic deck categories A1, A2 & A3 to BS EN 1991-1-1- Rapid response time that is comparable with radiator systems- Floor installation to current industry practises - no special installation requirements- Robust design deals with construction tolerances on site meaning a faster installation time.- Accepted by NHBC

REHAU Easy Control

With REHAU Easy Control you use the same heat source and primary pipework you use for a radiator system.- No electrical wiring as the system is totally mechanical - your plumber can carry out the complete installation- Improved control to ensure total comfort and rapid response for the homeowner- Easy operation for the homeowner through familiar controls similar to radiators- Works with dry and wet UFH systems - one control system throughout the house

Accepted by nHBc

3

1 infoRmAtion And sAfEty

Notes on this technical information

ValidityThis Technical Information is valid for the British Isles only.

NavigationAt the start of this Technical Information you will find a detailed table of contents with the hierarchical headings and the corresponding page numbers.

Pictograms and logos

Safety warning

Legal information

Important information which must be noted

Information on the internet

The advantages for you

Currentness of the Technical InformationFor your own safety and for the correct application of our products please check at regular intervals whether a more recent version of your Technical Information is available.

The issue date of your Technical Information is always printed on the bottom left-hand side of the back page.

You can obtain the current Technical Information from your REHAU sales office, specialist wholesaler or you can download it from the internet at:www.rehau.co.uk or www.rehau.co.uk/downloads

Safety warnings and operating instructions - For your own safety and the safety of other people, please read through all safety warnings and operating instructions carefully and completely prior to commencing assembly.

- Keep the operating instructions safe and have them available. - If you have not understood the safety instructions or the individual assembly guidelines or find them unclear, please contact your REHAU sales office.

- Non-compliance with the safety information may lead to damage to property and personal injury.

Use in line with the specificationThe REHAU underfloor heating systems must only be designed, installed and operated as described in this Technical Information or in the assembly instructions associated with the individual components. Any other use is not in accordance with the specification and is therefore not permitted.

Please contact your REHAU sales office for more detailed advice. Use in line with specification means compliance with all of the information in this Technical Information as well as the assembly, operating and maintenance instructions. No liability can be accepted for any use which is not in line with the specifications or inadmissible alterations to the product.

Observe all applicable national and international regulations relating to laying, installation, safety and the prevention of accidents when installing pipe systems, as well as the instructions in this Technical Information. Also observe the applicable laws, standards, guidelines and regulations (e.g. DIN, EN, ISO, BS, DVGW, TRGI, VDE and VDI) as well as regulations on environmental protection, regulations of the Employer’s Liability Insurance Association and specifications of the local public utilities companies. Please note the relevant status of the guidelines, standards and regulations in each case.

The design and assembly instructions relate directly to the REHAU product in each case. Some sections refer to generally applicable standards or regulations.

More detailed standards, specifications and guidelines relating to the design, installation and operation of drinking water and heating systems or systems for building services must also be observed and do not form part of this Technical Information.

Areas of application that are not included in this Technical Information (custom applications), require consultation with our technical applications department. Contact your REHAU sales office.

4

Prerequisites for personnel - Our systems must only be assembled by authorised and trained persons. - Work on electrical installations or pipework components must only be carried out by competent and authorised persons.

General precautions - Keep your workplace tidy and free from obstructions. - Make sure there is always sufficient light in your workplace. - Keep children, pets and unauthorised persons away from tools and the assembly areas. This applies particularly in the case of renovation work in an occupied area.

- Only use the components intended for the particular REHAU pipe system. The use of components from other systems or the use of tools that are not from the relevant REHAU installation system can result in accidents or other hazards.

Working clothing - Wear protective goggles, suitable working clothes, safety shoes, a hard hat, eye protection, ear protection, knee pads and a hairnet if you have long hair.

- Do not wear loosely fitting clothes or jewellery, these may get caught in moving parts.

During assembly - Always read and follow the operating instructions for the REHAU assembly tool used.

- Incorrect handling of tools can cause serious cut injuries, crushing or removal of limbs.

- Incorrect handling of tools can damage connecting components or cause leaks.

- The REHAU pipe cutters have a sharp blade. Store and handle these in such a way that there is no risk of injury from the REHAU pipe cutters.

- When cutting the pipes to length, keep a safe distance between the hand holding the pipe and the cutting tool.

- Never put your hand in the tool‘s cutting zone or tool or on moving parts during the cutting process.

- Following the expansion process the expanded ends of the pipe return to their original shape (memory effect). Do not insert any foreign objects into the expanded ends of the pipe during this phase.

- Never put your hand into the compression zone of the tool or on moving parts during the cutting process.

- Until the compression process is complete, the fitting may still fall out of the pipe. Risk of injury!

- During maintenance or retooling work and when changing the assembly area, always unplug the tool and prevent it from being switched on accidentally.

Operating parameters - If the operating parameters are exceeded, this leads to over stressing of the pipes and connections. Exceeding the operating parameters is therefore not permitted.

- Compliance with the operating parameters is to be ensured through safety and control systems (e.g. pressure reducer, safety valves and similar).

System-specific safety warnings - Take care and wear suitable protection when handling REHAU Easy Panels and Plywood panels.

- Observe relevant regulations and guidelines for lifting heavy items as panels are heavy.

- REHAU Wall thermostat and remote sensor contain ethyl acetate which is highly flammable and caustic. Please read health and safety information provided on the article data sheets.

5

At REHAU, all types of pipes are subjected to constant quality assurance and pass through numerous short and long-term tests to ensure the quality of the REHAU pipes. Several standard tests conducted in the REHAU test laboratory are described below. For polymer pipe materials subjected to thermal and mechanical loads, it must be observed that deformation and the strength depend on the temperature and the exposure time. To determine the permissible conditions for long-term loads, it is necessary to investigate the mechanical behaviour over a long period and at different temperatures. This also applies to pipes subjected to internal pressure.

Burst pressure testIn the burst pressure test, the pipes are subjected to a rising pressure in a test apparatus until the pipe ruptures. The burst pressure at room temperature is approximately seven times the maximum operating pressure.

Fig. 2-1 Results of a burst pressure test with the universal pipe RAUTITAN flex

Notch impact testThe resistance of the pipes to the effects of impact is tested in a notch impact testing device. A hammer-shaped pendulum strikes the tested pipe under controlled conditions. Pipes made of crosslinked polyethylene have a very high resistance to these severe mechanical effects. The depicted test example (see Fig. 2-2) shows a notch impact strength of the pipe without breaking at a temperature of –30°C.

Fig. 2-2 Universal pipe RAUTITAN flex in the notch impact testing device

2 REHAU qUAlity

Tension testIn a tension testing machine, the pipes are pulled longitudinally at high force under controlled conditions until they break. Pipes made of crosslinked polyethylene show an extremely high extensibility in comparison with metal pipes. The length of the extended pipe can be several times the original pipe length. The compression sleeve jointing technique cannot pull out under operating conditions: The pipe is not pulled out of the joint.

Fig. 2-3 Procedure of a tension test

Long-term testThe use of pipes in domestic installations requires a service life of 50 years or more. To determine the long-term effects, e.g. by temperature fluctuations, pressure and mechanical loads, the pipes are subjected to extreme conditions of temperature and pressure in long-term tests and are tested periodically by the test methods described above. The pipes are then photo-optically examined.

Fig. 2-4 Pipes in a long-term test (under pressure in a water bath)

The necessary parameters were developed on the basis of over 25 years of experience in the laboratory and in practice with numerous trials and extensive tests on pipes made of high-pressure crosslinked polyethylene. The pipes in the background with brown surfaces (see Fig. 2-4) have been tested since production began at REHAU in a test bath at 95 °C and 10 bar. Other tests are conducted according to the applicable standards and regulations. E.g, these are the measurement of the degree of crosslinking, shrinkage tests, ageing tests, temperature cycling tests, pulsing tests and many more.

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3 intRodUction to REHAU EAsy HEAt

3.1 System architecture

3.1.1 Traditional domestic heating systemsA boiler provides water with a flow temperature of up to 80ºC which is pumped through a 2-pipe system to individual radiators providing them with the required energy to heat the house. Depending on house size and installer preferences, boilers can either be a combination boiler or a system boiler. System boilers also heat up the domestic hot water stored in a cylinder using the same flow temperature as for the radiators (see Fig. 3-1). Combination boilers on the other hand heat cold mains water instantly and pump it to the outlets in a separate pipe system (see Fig. 3-2). Combination boilers allow for two different water temperatures to be set independently from each other, one for the heating system and another one for the domestic hot water.

Current building regulations typically demand two heating zones with independent time and temperature controls and a boiler interlock. Traditionally this is addressed by installing a master wall thermostat on each floor in the house and having a programmable two channel timer fitted.

Underfloor heating (UFH) systems are mainly fitted in screed floors, typically on the ground floor only and radiators are used on the upper floors, predominantly because most UFH systems do not offer an easy solution for joisted timber floors. As a consequence the water temperature in the heating system has to be reduced prior to it entering the UFH to prevent permanent damage to the floor. This is often achieved with a bespoke pump mixing arrangement and a manifold setup, requiring careful planning, sufficient space and corresponding controls. Furthermore each room fitted with UFH also features its own room thermostat which needs to be connected back to a central point. All this makes it hard for house builders to adopt UFH systems across their product portfolios.

Fig. 3-1 Typical installation with a system boiler

1. Expansion Vessel2. Pressure Gauge3. Safety Valve4. Heating System Filling Point5. Motorised Valve

12

345

55

Domestic HotWater Feed Tank

Domestic Hot WaterStorage TankDomestic Hot Water

To All OutletsRadiator

Radiator

Pump

Stop Cock

Mains Water

Mains Pressure ColdWater Supply To AllOutlets

Boiler

Fig. 3-2 Typical installation with a combination boiler

Mains Pressure ColdWater Supply To All Outlets Stop Cock

Mains Water

Radiator

Radiator

Domestic HotWater To AllOutlets

BoilerMotorised Valve Heating System

Filling Loop(Built into Boiler)

Motorised Valve

3.1.2 REHAU Easy Heat

Fig. 3-3 REHAU Easy Heat System

REHAU has a reputation for outstanding excellence within the building and construction sectors. This has been earned by providing quality products, expertise and customer support to the building and construction industry within the UK for over 50 years. Now with the desire to reduce CO2, emissions ever stronger and the need to reduce energy costs a driving factor, REHAU have developed the REHAU Easy Heat system.

The system comprises a unique product portfolio giving the developer, house builder and the home owner a choice of systems to enhance the energy saving potential of the building.

REHAU Easy Panel for joisted timber floors combined with the REHAU Easy Control System addresses the two biggest issues preventing the appearance of UFH system in main stream housing:- Simple & Fast installation processes which follow current standard industry

practises- Simple & Easy Control without complicated wiring and operating manuals

The REHAU Easy Heat system can be used with both an UFH only system and a mixed UFH/Radiator system. The system encompasses all types of domestic floor structure including screed floors, floating floors and suspended timber floors. All types of heat sources are suitable for use with REHAU Easy Heat from conventional, combination and system boilers, ground-source and air-source heat pumps, biomass, biogas and district heating systems.

Heating appliances that require manual fuel delivery can be used with UFH but if they go out due to lack of fuel the performance of the UFH will suffer.

7

The REHAU Easy Control compliments the Easy Heat floor systems perfectly by providing means of accurate and fast room control without requiring any electrical cabling. Its installation is easy and fast following the same method used for radiator system. A familiar and intuitive design enables the home owner to enjoy the new system without the need for training or complex instructions (Fig. 3-4).

Fig. 3-4 REHAU Easy Control & Combi-boiler

Stop Cock

Mains Water

Heating SystemFilling Loop(Built into Boiler)

BoilerDomestic Hot Water To AllOutlets

Mains Pressure ColdWater Supply To All Outlets

REHAUEasy Control

Motorised Valve

Motorised Valve

REHAUEasy Control

3.2 REHAU Easy Heat components

3.2.1 REHAU RAUTHERM universal pipeREHAU RAUTHERM universal pipe is made from cross-linked polyethylene, with a co-extruded EVAL oxygen diffusion barrier.

Cross-linking is the process of linking molecules in the polyethylene, giving much improved physical properties. REHAU was one of the pioneers of this process.

Peroxide-crosslinked polyethylene is designated PE-Xa. This method of crosslinking is conducted at high temperatures and pressure with the aid of peroxides. Here, the individual molecules of the polyethylene combine to form a three-dimensional network. This high-pressure crosslinking is characterised by crosslinking in the melt away from the crystallite melting point. Crosslinking occurs during the moulding of the pipe in the tool. This method of crosslinking ensures an even and very high degree of crosslinking over the entire cross section of even thick-walled pipes.

The EVAL oxygen diffusion barrier completely surrounds the base pipe and prevents the entry of oxygen into the system through the pipe work. This significantly reduces the risk of corrosion damage to ferrous components in the heating system. The EVAL barrier is highly resistant to abrasion and is notch resistant and thus capable of withstanding tough on-site conditions.

Fig. 3-9 Cross section of pipe

- Corrosion resistance of the pipes: No pitting- No tendency to form deposits, e.g. no scale build up- Polymer pipe material reduces sound transmission along the pipe- Good resistance to abrasion- Resistance to stress crack formation- Outstanding long-term stress rupture resistance at high temperatures of up

to 110ºC- Exceptional thermal ageing resistance- Kink resistance and kink damage resistance- Toxicologically and physiologically harmless

REHAU RAUTHERM universal pipe is supplied in sizes:- 12 x 1.1mm- 16 x 1.5mm- 20 x 1.9mm- 25 x 2.3mm- 32 x 2.9mm

Pipe specification- Working pressure – 6 bar at 95ºC – EN 15875- Malfunction temperate 100ºC at 3 bar- Recommended for nominal flow temperatures up to 83ºC- Operating pressure of 3.5 bar.

Minimum bending radiusREHAU RAUTHERM universal pipes are flexible and can be laid ‘cold’. The minimum bending radii are;

- (5 x D) at >0ºC- (3 x D) at 130ºC(D = pipe’s external diameter)

Pipe repair- Kinked pipe

A pipe can be repaired by gently and evenly applying heat to a length of 300mm each side of the kink. Care must be taken to keep the heat source (e.g. hot air gun, blow torch) constantly moving in order to avoid local overheating of the pipe. After about 3-5 minutes, the pipe will start to recover. Apply heat until the bore is fully recovered. Where the absolute minimum bending radius of 3 x D is required, heat should be applied as described above and then form the bend carefully.

Fig. 3-6 Ethylene, detaching double bond

Fig. 3-8 Crosslinked polyethylene (PE-X)

Fig. 3-5 Ethylene

Fig. 3-7 Polyethylene (PE)

Deep red opacity barrier

The polyethylene pipe (REHAU VPE)

The EVAL barrier coating

8

Avoid overheating the pipe at all times.When finished check that there is no damage to the glossy outer EVAL layer of the pipe.

- Leaking Pipe If a pipe has accidentally been drilled or damaged in such a way that water is leaking through the pipe wall, a REHAU EVERLOC™ coupler can be used to reseal the leaking section. Expose the damaged pipe and cut out a section extending at least 130mm to both sides of the damaged area and fit a new section of pipe using two REHAU EVERLOC™ couplers. After the couplers have been fitted wrap them completely in a suitable tape to protect from cement. REHAU fully warrants its REHAU EVERLOC™ fittings in screed systems.

Floor Systems RAUTHERM Universal Pipe RAUTHERM Universal Pipe

12 x 1.1mmArt. No. 138091

16 x 1.5mmArt. No. 136430

REHAU Tacker for screed floor N Y

REHAU RAUFIX for screed floor N Y

REHAU Easy Panel for timber joisted floor Y N

Table. 3-1 Pipe selection table

Property Tested to Value Units

Density DIN 53497 0.93 g/cm3

Young’s modulus DIN 53457 ~600 N/mm2

Impact resistance At +20ºCAt - 20ºC

DIN 53457

Without breaking Without breaking

Linear expansion co-efficient At +20ºCAt 100ºC

1.4 x 10-4

2.0 x 10-4

/K-1

/K-1

Thermal conductivity 0.35 W/mk

Oxygen permeability at 40ºC <0.1 mg/l d

Pipe roughness k 0.007 mm

Table. 3-2 Technical data

Floor Systems RAUTHERM Universal Pipe RAUTHERM Universal Pipe

Coil Size (m) 12 x 1.1mmArt No. 138091

16 x 1.5mmArt. No.136430

100 Y Y

240 Y Y

500 N Y

Table. 3-3 Delivery make-up

Fig. 3-10 REHAU EVERLOCTM joint

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3.2.2 Floor systems

3.2.2.1 REHAU Easy Panel

Fig. 3-11 REHAU Easy Panel

Fig. 3-12 REHAU Easy Panel cross section

Floor Covering

9mm plywood overlayREHAU proprietary grooved,structural P5 Particleboardwith system specificsurface laminate

Universal PE-Xa Pipe

Insulation

Joists

Ceiling Plasterboard

Typical Floor Structure for REHAU proprietary grooved, structural P5 Particleboardwith system specific surface laminate on an Engineered Joist System

REHAU Easy Panel is a structural floor solution for industry standard 600mm joist spacing on domestic deck categories A1, A2 & A3 to BS EN 1991-1-2002 (TRADA tested). The proprietary grooved particleboard with system specific surface laminate accepts 12mm REHAU RAUTHERM universal pipe and is combined with a plywood overlay. A full surface heat diffusion layer optimises the thermal performance. Installation of the panels is identical to that of a standard floor deck.

3.2.2.2 REHAU RAUFIX

Fig. 3-13 REHAU RAUFIX

Fig. 3-14 REHAU RAUFIX cross section

1. Wall2. Beading3. REHAU Edge Insulation Strip4. Floor Tiles5. Floor Levelling Compound6. Topping Slab / Screed7. RAUTHERM Universal pipe8. RAUFIX rail9. REHAU Vapour barrier10. Insulation11. DPM12. Structural slab13. Ground

32

1

13

1211

10987

6

54

This system is ideally suited for screed floors with a typical screed depth of up to 75mm. RAUFIX clip rails are secured with staples onto the insulation and membrane at regular intervals. The rails can be fixed onto most types of insulation and the 16mm REHAU RAUTHERM universal pipe accurately clipped in place making this a quick and effective installation method.

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3.2.2.3 REHAU Tacker

Fig. 3-15 REHAU Tacker

Fig. 3-16 REHAU Tacker cross section

32

1

14

131211

10987

6

54

1. Wall2. Beading3. REHAU Edge Insulation Strip4. Floor Tiles5. Floor Levelling Compound6. Topping Slab / Screed7. RAUTHERM Universal pipe8. REHAU Tacker staple9. Laminated Vapour Barrier10. REHAU Tacker sheet11. Additional insulation as required12. DPM13. Structural slab14. Ground

A system for screed floors with a typical screed depth of up to 75mm which provides significant time and cost savings during installation by combining previously separate installation steps into one. Tacker sheet comprises EPS sheet insulation, with a grid patterned polyethylene membrane. The 16mm REHAU RAUTHERM universal pipe is fixed in place using a staple gun, following the grid pattern marked on the PE sheet. By using this system time and cost is saved, the membrane no longer has to be rolled out and fixed in place and fixing rails are no longer required. This system is ideally suited for applications where underfloor is being installed in more complex areas and circuits need to avoid drains, pillars, alcoves etc. as the pipe can be laid around such obstacles.

System overview

REHAU floor system Base/SubstrateLoad distribution

(screed types)Pipe size in

mmTypicalpipe spacing Typical output

Imposed loads (uniform)

Wet Fit RAUFIX Tacker

- Solid Beam&Block- Pre-Stressed Beams

- Solid Base Slab

CTCA

CA-F

16 x 1.5mm 200-250mm Up to 100 W/m² Up to 5 kN/m²

Dry Fit Easy Panel - Joists- Solid Base Slab

REHAU Plywood 12 x 1.1mm 150mm Up to 80 W/m² Up to 2 kN/m²

Table. 3-4 System overview

11

3.2.3 Control systems

REHAU Easy ControlA proprietary mechanical control unit to regulate the water flow into both REHAU wet and dry UFH floor systems in lieu of manifolds. A versatile fixing bracket allows installation into both timber framed and block walls while providing a secure fixing method for a multitude of different fitting arrangements. With a maximum coverage of up to 25m2 it is ideally suited for all types of room configurations and sizes. The REHAU Easy Control comes with an integrated air vent, allows the isolation of the connected loops and completely replaces the traditional manifold setup in the UFH system.

REHAU wall thermostatThermostats and remote sensors complete the REHAU Easy Control system presenting the home owner with a very familiar and easy to use interface. No electrical wiring required.Comfortable, accurate and easy operation in a familiar design.Temperature range 6 - 28ºC, frost protection 6ºC.

NEA HT programmable master room thermostatREHAU proprietary heating thermostat with stylish design and illuminated LCD display showing current time and temperature. Three button control with valve exercise and frost protection.

Operating modes: Automatic, standard, comfort and permanent off.Three heating programmes per day and additional party/ holiday mode.Used in conjunction with REHAU 2-port zone valve to achieve time & temperature control per floor in accordance with Building Regulations Part L.

REHAU motorized zone valve – 22mmQuiet, motorised, normally closed, zone valve with potential free end switch for electrical control of pump and/or boiler. Manual lever for filling & draining the system and minimal power consumption.

Used in combination with the REHAU NEA HT thermostat to achieve time & temperature control per floor in accordance with Building Regulations Part L.

REHAU thermostatic mixing valve – 22mmQuick reacting thermostatic blending valve for thermal loads up to 15kW. Optimised for flow rates in underfloor heating systems. Wax capsule technology ensures stable mixed water temperature. Suitable for blending the flow and return to achieve a stable system temperature in underfloor heating systems between 35ºC to 60ºC. Used in installations with system boiler or other energy sources where supplied flow temperatures exceed limits for underfloor heating systems.

REHAU high limit thermostatOvertemperature thermal cut out device with auto reset. Measures the temperature on the surface of the primary flow pipe to protect underfloor heating system in case of a malfunction of the energy source or water mixing equipment as required by Building Regulations and BS EN 1264.

Energy efficient pump 25/1-6-130Glandless circulation pump with threaded connection, blocking-current proof EC motor and integrated electronic power control. Two pre-set control modes for optimum load adjustment and LED display for commissioning. Suitable for heating applications with water temperatures of up to 95ºC and max. operating pressure of 6 bar. Used in installations with thermostatic mixing valves to pump the blended water through the UFH system.

Fig. 3-17 REHAU Easy Control

Fig. 3-21 REHAU thermostatic mixing

valve – 22mm

Fig. 3-22 REHAU high limit thermostat

Fig. 3-23 Energy efficient pump 25/1-

6-130

Fig. 3-18 REHAU wall thermostat

Fig. 3-19 NEA HT programmable

master room thermostat

Fig. 3-20 REHAU motorized zone valve

– 22mm

12

3.2.4 Accessories

REHAU corrugated sleeveTo protect RAUTHERM universal piping where pipes are fed into the distribution manifold, routed across movement joints, through walls and changes in levels.

It also provides protection against damage to the capillary tube of the wall thermostat/remote sensor of the Easy Control system.

REHAU EPS floor insulationREHAU EPS insulation is made from CFC free polystyrene and meets the new European manufacturing standard EN 13163.

REHAU EPS floor insulation is supplied in two grades:- EPS 150- EPS 100

Can be used as additional insulation for:- REHAU RAUFIX- REHAU Tacker

Technical dataEPS 100 25mm

EPS 100 25mm

EPS 150 25mm

EPS 150 50mm

REHAU Art. No. 200386 200414 200393 200413

Dimensions in mm (Length x Width x Thickness)

2400x1200x25 2400x1200x50 2400x1200x25 2400x1200x50

Make-up Single Board Foldable Board Single Board Foldable Board

Thermal conductivity 0.036 W/mK 0.036 W/mK 0.035 W/mK 0.035 W/mK

Compression strength 10%

>100 kPa >100 kPa >150 kPa >150 kPa

Breaking strength >150 kPa >150 kPa >200 kPa >200 kPa

Designation to EN 13163 E EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1Fire class to EN 13163 E F F F F

Table. 3-5 System overview

REHAU edge insulationThe profiled PE (Polyethylene) wall of the REHAU Edge Insulation allows for easy fitting to walls, corners,projections and recesses. It also helps to reduce heat bridging and offers the required movement of 5mm for heating screeds according to DIN 18560.

The adhesive strip on the back of both the insulation and clear foil flap guarantee excellent adhesion and quick assembly. The foil base is tear resistant and also prevents moisture and water from the screed reaching the EPS floor insulation.

Suitable for:- REHAU Tacker- REHAU RAUFIX

Assembly1. Remove the protective film from the adhesive strip on the back of the edge

insulation.2. Fit the edge insulation around the perimeter of the room with the REHAU

Logo uppermost.3. When the REHAU EPS Floor Insulation has been laid, pull off the protective

film from the adhesive strip on the foil flap and stick down firmly.

All edge insulation joints must have an overlap of 5cm

Technical dataMaterial Wall PE (polyethylene)

Material foil flap PE (polyethylene)

Height 180mm

Thickness 10mm

Length foil flat 280mm

Table. 3-6

REHAU PE membraneThe REHAU PE Membrane is tear resistant and meets the requirements set out for DIN 18560. It prevents water and moisture from the screed reaching the EPS Insulation and therefore reduces heat bridging.

If used with an anhydride (flow) screed, all joints must have an overlap of at least 80mm or must be taped in accordance with BS 1264.

Adhesive tape and dispenser- High level of adhesion- High degree of tar resistance- Lightweight tape dispenser

Suitable for:- REHAU Tacker- REHAU RAUFIX

The REHAU tape should be used with every REHAU Tacker system and anhydride (flow) screed.

REHAU pipe cuttersAvailable with quick action or ratchet mechanism- Quick and safe cutting action- Burr free cut faces

Fig. 3-25 REHAU EPS floor insulation

Fig. 3-26 REHAU edge insulation

Fig. 3-27 REHAU PE membrane

Fig. 3-28 Adhesive tape and dispenser

Fig. 3-29 Quick-action mechanism

Fig. 3-24 REHAU corrugated sleeve

13

REHAU pressure pump- Pressure test pump for pressure

testing- Pressure testing possible with

water and anti-freeze- Filling and pressure testing in one

operation

The REHAU pressure pump can be used to pressure test all REHAU underfloor heating systems according to BS 1264-4.

REHAU pipe unwinder 300REHAU pipes carrying a medium are quickly and easily installed at the construction site with the REHAU pipe unwinder.

- RAUTHERM universal pipe 12 x 1.1mm up to maximum coil size of 240m



Assembly- Loosen transportation securing screw- Fold out moving feet- Pull out foot extensions- Fold out support arms- Fold securing arms up- Pull out extension up to the maximum ring height/width

To avoid any unwanted movements after unwinding, you can tighten the safety screw if necessary.

Attention! Danger of injury by turning parts

Technical dataDiameter in total 1.4m

Height when fully assembled Approx. 86cm

Material Galvanised Steel

Weight without pipe Approx. 12.5kg

Table. 3-7

Fig. 3-30 Pressure pump

Fig. 3-31 Pipe unwinder 300

Fig. 3-32 REHAU 90º pipe bend former

REHAU 90º pipe bend formerREHAU pipe bend formers provide a stable and defined way of fixing the pipe below the manifold or REHAU Easy Control unit. They can also provide additional support in areas of tight bend radii, e.g. installations with 20mm pipe spaced at 100m centres. In such cases the bend formers prevent the pipe from kinking every time the pipe is heated up.

14

4 tRAnspoRt And HAndling

4.1 Handling the pipes and system components

Fig. 4-1 Protect pipes against sunlight

Store and transport pipes and components protected against UV radiation.

Avoid damaging the pipes and system components:- Load and unload with due care.- Only transport in a fashion suitable for the materials.- Do not drag over floors or concrete surfaces.- Store on a flat surface with no sharp edges.- Protect against mechanical damage.- Protect against dirt, drilling dust, mortar, grease, oil, paint, solvents,

chemicals, humidity, etc.- Protect against sunlight, e.g. with an opaque film or similar material.- Protect against long sunlight during the building phase.- Only unpack shortly before laying.

Fig. 4-2 Do not store pipes on sharp-edged surfaces

The REHAU Easy Heat components should be transported and stored under expert supervision.

4.2 Handling & storage of REHAU Easy Panels & REHAU plywoodFor REHAU Easy Panel / plywood follow the industry standard guidelines for the movement, handling, storage, conditioning and installation of standard particleboard and plywood. REHAU Easy Panels and plywood are heavy and care must be taken when handling the panels. All manual handling procedures must be followed. The edges of the panels can be sharp, therefore wear suitable hand protection when handling.

Following delivery to site the panels should be stored in a dry covered building on a flat floor with any retaining bands cut as soon as possible after delivery. If external storage is required then the boards must be stacked flat off the ground, on 5 equally spaced bearers. The panels should then be covered with secure weatherproof sheeting to prevent the ingress of moisture to all parts of the panels.

15

5 instAllAtion

5.1 REHAU Easy Panel

REHAU Easy Panel is a proprietary grooved T&G P5 particleboard with system specific surface laminate which accepts 12mm REHAU RAUTHERM universal pipe. The full surface laminate diffuses the heat and optimises the thermal performance. It is available in industry standard sized panels of 2400mm x 600mm x 22mm.

On completion of the pipework install the floor surface is required to have a 9mm REHAU plywood topping. The REHAU Plywood top sheet is specifically matched to the proprietary REHAU Easy Panel.

When fitted with the REHAU Plywood to REHAU requirements, the REHAU Easy Panel is suitable for installation on joist spacing up to 600mm, meeting requirements of EN 12871 for floor load categories set out in table 5-1 as defined in NA to BS EN 1991-1-2002.

5.1.1 Categories for residential, social, commercial and administration area including additional sub categories for the UK.

Category Qk kN/m2 Qk kN

A1 1.5 2.0

A2 1.5 2.0

A3 2.0 2.0

Table. 5-1 Category of loaded area and imposed loads

Extract from BS EN 1991-1-2002Category A1, All usages within self-contained dwelling units (a unit

occupied by a single family or a modular domestic and student accommodation unit with a secure door and comprising not more than six single bedrooms and an internal corridor. Communal areas (including kitchens) in blocks of flats. Note for communal areas in other blocks of flats see A5, A6 and C3

Category A2, Bedrooms and dormitories, except those in self-contained single family dwelling units and in hotels and motels

Category A3, Bedrooms in hotels and motels; hospital wards; toilet areas

Fig. 5-2 REHAU plywood top sheet


16

5.1.2 Conditioning of REHAU Easy PanelsThe REHAU Easy Panels should be stored in a dry and weather tight area of installation and left to acclimatise to the conditions in this area. Panels should be stored flat on a minimum of 5 equally sized bearers spread evenly on the floor, with 3 equally sized spacers placed evenly between each panel to allow free air movement to the top and bottom surfaces.

A period of approx. 2-3 days is required for conditioning of the panels. REHAU recommend that the floors should only be installed when the humidity is the same as when in service, and only when the recommended conditioning is complete.

The flooring panels can expand or contract slightly as they react to the climatic conditions.

5.1.3 Installation of REHAU Easy PanelsAll instructions should be followed in conjunction with the industry standard particle board installation guidelines.

All Tongue & Groove joints on the boards must be glued on all edges with a suitable PVA adhesive. This will strengthen the joint and reduce the risk of noise. The adhesive should be liberally applied to coat both surfaces of the tongue before fitting fully into the groove of the adjoining panels.

PVA adhesive to durability class D3 of BS EN 204:2004 is recommended.

In all applications REHAU Easy Panel should not be fitted tight to any wall. REHAU recommend a minimum gap of 12mm between the panel edge and any wall or solid structure that penetrates the floor area. This includes electrical conduits, ducts and pipework. If the panels are to be fitted in long flooring runs then a gap of 2mm per metre run must be allowed for with the minimum being 12mm.

For floors where the movement gap cannot be dealt with at the perimeter alone or which are in excess of 6 metres long, e.g. corridors, intermediate expansion gaps (minimum 12mm), should be incorporated into the floor.

To maintain the perimeter gap, packers or wedges can be used. Remove these immediately after the adhesive has set.

The movement gap must not be obstructed with debris.

All REHAU Easy Panels should be protected from moisture including wet trades and any water spillage at all times.

When applying heat to the panels for the first time. Ensure the heat is increased gradually. REHAU recommend that the initial heat up period as described within BS EN 1264 is carried out.

Step 1Apply a 6mm bead of PVA Wood adhesive to the beams and noggins in the area that is about to be directly laid.

Step 2Panels should be fixed at the perimeter using ringshank nails or screws at 200-300mm centres. All fixings should be flush or just below panel surface.

Step 3A liberal application of suitable PVA wood adhesive should be applied to both edges of the tongue and the groove of each panel to ensure that the entire joint is bonded.

When joining the short edge carefully align the panels ensuring the pipe channels are in line with each other for a smooth installation of the UFH pipework (Fig. 5-7).

Step 4Continue laying boards in a staggered format. Ensuring the short end of the panel is fully supported

Until the REHAU plywood layer is fixed in place, the fitted deck is a temporary floor only, and must not be subjected to the full final loads.

Fig. 5-3 Adhesive joist application

Fig. 5-4 Perimeter panel fixing

Fig. 5-5 Adhesive tongue & groove

application

Fig. 5-7 Aligning panelsFig. 5-6 Panel fixing

17

5.2 Primary flow and return including flow controls

5.2.1 System configurationREHAU Easy Control requires the primary flow and returns to be installed as a 2-pipe system with routing of pipes inside the building being identical to that of a radiator system. The required components for the primary connections from the energy source to the individual REHAU Easy Controls are the same as for a radiator system as long as the selected energy can supply the flow temperature required for the REHAU Easy Heat system (typically 35ºC – 55ºC). This is generally the case for combination boilers. For other energy sources, e.g. system boilers, REHAU also provides the required components for blending the heating water down to the required temperature which include a 3-port thermostatic mixing valve, energy efficient pump, high temperature limit pipe thermostat and all associated RAUTHERM universal pipe fittings. REHAU recommend using its RAUTHERM Universal pipe system for the primary flow and returns.

Current Building Regulations require any space heating system to have a minimum of two independent heating zones, each with its own time and temperature control. This can be achieved by using a REHAU NEA HT programmable master thermostat together with a REHAU 2-port zone valve in every heating zone. The connected zone valve is activated by the room thermostat and in turn switches the energy source through its auxiliary switch. For a typical installation, this means a total of two such heating zones exist, the downstairs living area and the upstairs sleeping. Building regulations also demand that every room should have its own temperature control. The REHAU Easy Control fulfils this requirement. See Fig. 5-9 – 5-10. for typical hydraulic schematics dependent on the selected energy source.

Installations with heat pumps can have a wide variety of different system setups but the general principle regarding mixing equipment still applies: if the setup can provide a flow temperature for the heating system at the required temperature for the REHAU Easy Heat system, no further mixing components are required.

Fig. 5-8 Two heating zones with combination boiler

Stop Cock

Mains Water

Heating SystemFilling Loop(Built into Boiler)

BoilerDomestic Hot Water To AllOutlets

Mains Pressure ColdWater Supply To All Outlets

REHAUEasy Control

Motorised Valve

Motorised Valve

REHAUEasy Control

Fig. 5-9 Two heating zones with system boiler

6

23

45

5

5

6 78

1. Expansion Vessel2. Pressure Gauge3. Safety Valve4. Heating System Filling Point5. Motorised Valve6. Pump7. 3 Port Mixing Valve8. High Limit Stat

Domestic HotWater Feed Tank

Domestic Hot WaterStorage TankDomestic Hot Water

To All Outlets

Stop Cock

Mains Water

Mains Pressure ColdWater Supply To AllOutlets

Boiler

REHAUEasy Control

REHAU Easy Control

1

5.2.2 Flow and return pipesDependent on the required system configuration install the pipes from the energy source to the selected positions for each REHAU Easy Control (see following section on recommended positions) following current industry standards and practises. REHAU Easy Control must be connected using the corresponding REHAU connection unions which are available for REHAU pipe sizes 12 x 1.1mm and 16 x 1.5mm and 15mm copper pipes. For installation of REHAU Universal pipe and fittings follow the current REHAU Technical Information for this system.

5.2.3 Mixing components for flow temperature (if required)Please refer to the installation information / data sheets provided with each article.

A high temperature limit pipe thermostat which when activated closes the zone valve is recommended for every installation to protect the floor structure.

5.2.4 REHAU zone valve and wiring for REHAU NEA HTThe REHAU 2-port zone valve with 22mm compression connections is activated by the NEA HT master room thermostat and allows heating water to reach all REHAU Easy Controls in a single heating zone. Its volt-free auxiliary switch is triggered when the valve is fully open and activates the energy source (see Fig. 5-10 & 5.11). The REHAU NEA HT programmable master room thermostat should be located in an easily accessible location and will provide the time control and boiler interlock for each heating zone required by current building regulations. Most common locations include entry halls downstairs and landings upstairs but must not be an external wall.

Fig. 5-11 Typical wiring configuration REHAU NEA HT & REHAU zone valve (MV) and

optional REHAU high temperature limit thermostat (HLT)

NL

NEA HT*230V

230V 0.2AResistive Load

230V ACL N

HLT MV

HLT High Limit Thermostat

MV Motorised ValveLoad

NL

NeutralPhase

Key

Fig. 5-10 REHAU zone valve

18

To ensure trouble free operation and efficient control the NEA room thermostat is best positioned in a draft-free area and at 130cm from the floor. Do not position the thermostat near any heat source, behind curtains, direct sunlight or in an area of high humidity. Observe the installation and wiring instructions provided with the NEA HT.

Both components require a permanent 230V power supply. Please refer to Fig. 5-11 for wiring configurations.

5.3 REHAU Easy Control with fixing bracketREHAU Easy Control together with the REHAU Wall Thermostat or Remote Sensors is a mechanical control unit which does not require any power and automatically regulates the flow of water into the REHAU floor heating system. A manual air vent allows the commissioning process to follow standard industry practises which can be further assisted with an optional air valve. Through the integrated balancing & isolating valves the connected pipes in the floor can be fully isolated. Use the REHAU splitter to connect two UFH loops for a maximum heated area of 25sqm.

Only use REHAU connecting unions for all pipe connections.

Step 1:Before installing ensure the following preconditions are met:- Building is weather proof- Internal stud work and/or block walls

for separating walls are in position (but not plaster boarded/plastered)

- For joisted timber floors the REHAU Easy Panel system has been installed

- You are familiar with the REHAU Easy Control outlets (Fig. 5-13)

Step 2:Identify a suitable wall position making sure:- the centre of the unit sits around 300mm above the finished floor level- the unit will be aligned as much as possible with the flow&return pipes from

the UFH floor- the selected routing for the capillary tube back to the corresponding REHAU

Wall thermostat / remote sensor location does not exceed the maximum reach of the capillary tube.

Step 3:Install the provided wall fixing bracket as shown in Fig. 5-14 so that the complete unit sits fully inside the wall structure. The wing with the smaller holes can be left flat if fixing is required perpendicular to the REHAU Easy Control

- Both wings can be folded easily without tools- REHAU Easy Control unit can be installed in any orientation as long as the

connected actuator or thermostatic head is not facing downwards- Installation into block walls is identical to that into stud walls. Chase work

may be required.

Step 4:Attach the REHAU Easy Control to the wall fixing bracket by passing the UFH outlet connections through the large holes and hold it in place by tightening both REHAU connecting unions onto the UFH outlets (Fig. 5-15).

Step 5:Mark the distance from the primary outlets to the supporting stud on the base studwork and drill two 20mm holes through the base plate into the floor void below to provide entry points for the primary flow and return pipe work from the energy source. Holes must be drilled in the centre of the base plate (Fig. 5-16).

Step 6:Drill two more 15mm holes, 50mm apart from each, through the base plate into the floor void below taking care to drill them in the centre of the base plate. The first should be around 260mm from the centre of the wall fixing bracket. These are the entry points for the UFH flow & return pipes. Clear it from any obstructions so a 12mm pipe can freely move inside it (Fig. 5-17).

Fig. 5-12 REHAU Easy Control with

wall fixing bracket

Fig. 5-14 Installing wall fixing bracket

Fig. 5-15 Attaching REHAU Easy Control

Fig. 5-16 Position primary F&R

Fig. 5-17 Position UFH F&R

Air Vent

BalancingScrew

IsolatingValve

UFH Flow

UFH Return

Primary FlowPrimary Return Primary FlowPrimary Return Primary FlowPrimary Return Primary FlowPrimary Return

BalancingScrew

IsolatingValve

Air Vent

UFH Flow

UFH Return BalancingScrew

IsolatingValve

Air Vent

UFH Flow


IsolatingValve

Air Vent

UFH Flow

UFH Return

Primary Return Primary Flow

IsolatingValve

BalancingScrew

Air Vent

UFH Return

UFH Flow UFH Flow

UFH Return

IsolatingValve

BalancingScrew

Air Vent

UFH Flow

UFH Return

IsolatingValve

BalancingScrew

Air Vent

Primary FlowPrimary Return Primary FlowPrimary Return

UFH Flow

UFH Return

Air Vent

BalancingScrew

IsolatingValve

Primary FlowPrimary Return

Fig. 5-13 REHAU Easy Control outlets

19

Step 7:Pass the primary flow and return pipes (RAUTHERM Universal 16x1.5 or 15mm copper) through the holes for the primary connections and connect to the REHAU Easy Control using the correct REHAU connecting unions (Fig. 5-18).

5.4 Laying UFH pipes

5.4.1 REHAU Easy Panel

Immediately after completing the pipe laying a pressure test should be carried out (see section 6.2 for details). REHAU plywood should be installed straight after the successful pressure test to protect the pipes and deck panels from any accidental damage through other trades. See section 5.5.

Ensure a minimum distance of 150mm to all walls when laying the pipes by:- always using the REHAU router jig for routing bends- leaving the channel closest to the wall free of pipe if necessary

Step 1:Before pipe can be installed the following must be completed:- Building to be weather proof- REHAU Easy Panel has been fully installed to REHAU specification- Internal stud work in position for separating walls (but not plaster boarded)- All REHAU weather tape has been removed (if fitted).

Step 2:Identify the UFH pipe work runs within the heated area.

Step 3:Identify and mark the circuit returns on the REHAU Easy Panels following a single meander pattern. Take care as not all channels at any one end will have routed returns.

Step 4:Identify the two points where the UFH pipe will enter and exit the REHAU Easy Panels from the void below. These points must be at least 115mm from any wall. Drill a 15mm hole into the void below at an angle of approximately 30° at each point in line of the channel. The holes should allow free movement of the pipe from above to below the deck to enable connection back to the REHAU Easy Control (Fig. 5-19).Alternatively create a 5-10cm long and 15mm wide slot in the channel at each entry and exit point.

Goggles, suitable dust mask & ear protection must be used when routing the panels

Step 5:Rout the return bends using the REHAU router jig securely positioned in place with the provided locking pins (Fig. 5-20). If required the jig can also be screwed down through the 4mm screw hole. A 12/6 TC radius cutter with a 6.3mm radius, a 12.7mm width and a 19mm cutting depth is required. The router must be fitted with a 30mm guide bush and the cutting depth set so it does not exceed 13mm from the foil surface of the REHAU Easy Panel.

To ensure the final structural integrity of the deck, never:- rout deeper than 13mm from the

foil surface- exceed 2 full return routs or equivalent

number of smaller routed sections in each panel above any one joist space. Any panels having more routs must be removed and replaced (Fig. 5-21).

Step 6:When the routing operation is complete, clean the floor area of all debris (timber cuttings from routing, etc) paying particular attention to the pipe channels which have to be clean and clear of any debris to accept UFH pipe.

Step 7:Place the REHAU pipe un-winder away from the room being installed and place the coil of 12mm REHAU RAUTHERM universal pipe on it. Cut the outer set of string and pull the pipe from the pipe un-winder.

Step 8:Tape the end of the pipe to prevent any possibility of debris entering the pipe then thread the taped end through the 15mm exit hole in the deck. Run this pipe below the floor deck back to the REHAU Easy Control position following normal practises employed for plumbing work. If holes have to be drilled through the joists these should be positioned to the manufactures instructions and to current Building Regulations. All holes through joists should be lined to prevent expansion / contraction noise as indicated in BS EN 806-4:2010. Part 4.7.1: Allowances for thermal movement and prevention of noise.

Step 9:Pass the taped pipe end back up through the previously drilled 15mm hole in the floor and stud work. Remove the tape and using the correct REHAU connecting unions connect it to the UFH return port of the REHAU Easy Control (Fig. 5-22).

115mm

30º

Fig. 5-20 Router jig

Fig. 5-22 Connect UFH return

Fig. 5-21 Maximum number return bends

Fig. 5-18 Connected primary F&R

including optional air vent

Fig. 5-19 entry/exit points in floor deck

20

Step 10:Continue then to place the pipe into the routed UFH channels starting from the exit hole working your way back towards the pipe entry point and the REHAU Easy Control. Take care to fully push the pipe into the channels so that it sits flush with or slightly below the panel surface (Fig. 5-23).

Step 11:Connect the UFH flow with the correct REHAU connecting unions to the UFH flow port of the REHAU Easy Control by passing it through the 15mm entry hole in the panels into the void below and back up again through the panels and base plate of the stud wall. Tighten all union connections with a min of 20Nm torque (Fig. 5-24).

Component selection table Components

Dimensions

AverageQuantity

REHAU Easy Panel Art.No. 219685-001

2400 x 600 x 22mm 0.7 pieces per m2 deck area

REHAU plywood Art.No. 219666-001

2440 x 1220 x 9mm 0.35 pieces per m2 deck area

REHAU RAUTHERM universal pipe Art.No. 138091-103Art.No. 138091-243

12 x 1.1mm 6.7m per activated m2 deck area

REHAU weatherproof tape Art.No. 218951-001

50m x 50mm 8.7m per m2 deck area

REHAU router Jig Art.No. 218949-001

300 x 330 x 12mm 2x per installation

Table. 5-2

Fig. 5-23 Lay UFH pipe

Fig. 5-24 Connect UFH flow


Typical floor structure

Floor covering with max R-value of 0.15 W/mK

REHAU Plywood

REHAU Easy Panel

REHAU RAUTHERM Universal pipe

100mm Mineral Wool

Routed Channels

Timber Joists

21

5.4.2 REHAU RAUFIXMake sure site requirements for

installing underfloor heating are met: rooms cleared, installation area dry, sealed to the elements, flat even floor, and surface free of irregularities.

Fit REHAU Edge insulation around the perimeter and internal walls, columns, drains and door frames ensuring a 50mm overlap at joints (insulation already comes with self adhesive tape on the back).

Lay insulation ensuring the following:- Stagger the joints as in a brick wall.- Insulation boards are butted tightly up against each other.

Lay polyethylene membrane over floor insulation, ensuring that:- It is placed up the walls, above the finished floor height- The membranes overlap each other by 80mm- The membrane must be watertight when used with an Anhydride (flow) screed, by taping the joints and the edge insulation.

Fix rails to the EPS floor insulation using staples every 400mm. Rails must be fixed 800mm from walls and obstructions to allow for the bending radius of the pipe. The remainder of the area should have rails laid at 1m centres.

In areas of pipe bends/returns, rail trim offs can also be used to fix the pipe bends directly to the floor insulation and to ensure uniform spacing.

Cut a short piece of corrugated sleeve (at least 1m long) and slide it over the pipe end. Sleeve is to protect pipe from shearing where it enters the screed.

Connect REHAU pipe to the REHAU Easy Control unit using the matching REHAU connecting unions.

1

2

3

4

5

6

7

8

1

3

4

2

5

- Clean- Dry- Sealed- Flat

6

1000mm

Floor Insulation

Overlap

Floor Insulation

7

8

Fig. 5-26 REHAU RAUFIX

22

Start laying the circuit by simply “snapping” the pipe into the RAUFIX/Railfix rails. The circuit is laid in the double meander pattern as per the underfloor heating design.

When installing pipe in door frames, holes through walls or across planned expansion joints, always put on a section of corrugated sleeving in this area to allow free movement of pipe. Sleeving can be split along the length and clipped over the pipe.

Before connecting return to REHAU Easy Control, slide on another 1m long corrugated sleeve section.

Install remaining circuits in the same way, as detailed in steps 7 to 11.

Rails to be spaced evenly at 1m and 0.8m from walls.

40mm Staples set at an angle for 25mm insulation.


16mm Pipe Art. No. 136430

Average quantity

RAUFIX staples Art. No. 268118, 40mm Art. No. 259268, 50mm

Y Y

3 pieces per m2

3 pieces per m2

RAUFIX rail Art. No. 244248 with barbs Art. No. 240241

Y Y

1m per m2

1m per m2

Edge insulation Art. No. 264411

Y

length of all perimeter walls

Corrugated sleeve Art. No. 137140

Y

1m per REHAU Easy Control port

REHAU adhesive tape Art. No. 265942

Y

1m per m2

REHAU tape dispenser Art. No. 261959

Y

-

Polyethylene membrane Art. No. 256054

Y

1m2 per m2 floor

Table. 5-3

Staple selection table Polystyrene insulation

40mm Staple Art. No. 268118

50mm Staple Art. No. 259268

EPS 100 25mm Art. No. 264175

Y

N

EPS 100 50mm Art. No. 264185

N

Y

Table. 5-4 Staple Selection Table


Floor covering with max. R-value of 0.15m2K/W

75mm thick sand/cement screed

REHAU RAUFIX rail

Insulation with REHAU PE membrane

REHAU edge insulation

REHAU RAUTHERM Universal PE-Xa pipe

Concrete floor slab with damp proof membrane

Fig. 5-27 REHAU RAUFIX cross section

9

10

9

10

1000mm

11

11

12

12

23

5.4.3 REHAU Tacker systemMake sure site requirements for

installing underfloor heating are met: rooms cleared, installation area dry, sealed to the elements, flat even floor and surface free of irregularities.

Fit REHAU Edge insulation around perimeter and internal walls, columns, drains and door frames ensuring a 50mm overlap at joints (insulation already comes with self adhesive tape on back).

Lay Tacker Sheet boards ensuring the following:- Printed foil faces- Grid lines up across the joints- Stagger the joints as in a brick wall- Each joint is covered with a foil overlap

(Tacker Sheet already comes with a foil overlap on two adjoining sides)

- Tacker Sheets are butted tightly up against each other.

Tape all joints to ensure no water from the screed passes underneath the boards.

Remove cover from adhesive tape from the foil on edge insulation and fix it to Tacker Sheets.

Cut a short piece of corrugated sleeve (at least 1m long) and slide it over the pipe end. Sleeve is to protect pipe from shearing where it enters the screed.

Connect REHAU pipe to the Easy Control unit using the matching REHAU connecting unions.

1

3

2

4

5

- Clean- Dry- Sealed- Flat

1

2

3

4

5

6

6

7

Tacker Sheet Tacker Sheet

Foil overlap

1000mm

Fig. 5-28 REHAU Tacker system

7

24

Start laying the circuit by simply stapling the RAUTHERM pipe onto the Tacker Sheet using the correct sized REHAU Tacker staples and staple gun (see table overleaf for details). Set staples at a maximum interval of 400mm.

To push a staple into the insulation, simply push down the handle of the gun fully and allow it to travel back up again completely, before pushing in the next staple.

- Always ensure there is a sufficient number of staples on the carrier to allow correct feeding of the staples into the staple gun

- If staples are pulled out of the Tacker Sheet, tape over the punched holes to keep top surface water resistant.

When installing pipe in door frames, holes through walls or across planned expansion joints, always put on a section of corrugated sleeving in this area to allow free movement of pipe. Sleeving can be split along the length and clipped over the pipe.

Before connecting return to REHAU Easy Control unit, slide on another 1m long corrugated sleeve section.

Install remaining circuits in the same way as detailed in steps 6. to 10.

- Printed foil facing upwards.- Use correct size of staples for selected pipe size.- Tape all joints to protect insulation from screed moisture.- Use staples at least every 400mm.


16mm RAUTHERM Pipe Art. No. 136430

Average quantity

Tacker staples Art. No. 240221, grey colour

Y

2.5 pieces per metre pipe

Tacker gun multi Art. No. 227835

Y

Tacker sheets Complete range

Y

0.35 sheets per m2

Edge insulation Art. No. 264411

Y

Length of perimeter

Corrugated sleeve Art. No. 137140

Y

1m per REHAU Easy Control port

REHAU tape Art. No. 265942

Y

1.25m per m2

REHAU tape dispenser Art. No. 261959

Y

REHAU EPS cutter Art. No. 249632 Art. No. 24652, spare cutter blades

Y Y

Table. 5-5 REHAU Tacker component table

Technical dataEPS 100 25mm

EPS 100 25mm

EPS 150 25mm

EPS 150 50mm

REHAU Art. No. 200386 200414 200393 200413

Dimensions in mm (Length x Width x Thickness)

2400x1200x25 2400x1200x50 2400x1200x25 2400x1200x50

Make-up Single Board Foldable Board Single Board Foldable Board

Thermal conductivity 0.036 W/mK 0.036 W/mK 0.035 W/mK 0.035 W/mK

Compression strength 10%

>100 kPa >100 kPa >150 kPa >150 kPa

Breaking strength >150 kPa >150 kPa >200 kPa >200 kPa

Designation to EN 13163 E EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1

EN 13163-T1-L1 W1-S2-P3-

DS(80,-)1Fire class to EN 13163 E F F F F

Table. 5-6 Overview of EPS insulation


Floor covering with max. R-value of 0.15m2K/W

75mm thick sand/cement screed

REHAU RAUTHERM universal PE-Xa pipe

REHAU Tacker sheet with laminated PE membrane and printed installation grid

Concrete floor slab with damp proof membrane

REHAU edge insulation

REHAU Tacker staple spaced at 400mm

Fig. 5-29 REHAU Tacker system cross section

1000mm

10

10

Manifold

11

11

8

9

8

9

25

5.5 REHAU plywood

A structural, square edge, 3ply plywood to BS EN 636 in industry standard size 2440mmx1220mmx9mm which together with the REHAU Easy Panels forms a structural deck in a suspended floor applications for timber joist spacings of up to 600mm.

Only when fitted with REHAU plywood to REHAU requirements can the REHAU Easy Panel system achieve the load requirements for deck categories A1, A2 & A3 as set out in NA to BS EN 1991-1-2002.

Step 1:Before the REHAU plywood can be installed the following must be in place:- REHAU Easy Panel has been fully

installed to REHAU specification- Building is weather proof and REHAU

Easy Panels are completely dry- REHAU RAUTHERM universal pipe

has been fitted to REHAU Easy Panels- Successful pressure test of the UFH

loops

Step 2:For every room cut the panels to the required size and starting in one corner and with the long panel edge perpendicular to the UFH pipes. Stagger the panel joints so they do not coincide with the joints of the REHAU Easy Panels. REHAU and NHBC recommendations are to fix the panels at each corner and every 0.3m in each direction across the entire panel to the deck to minimise impact sound (Fig.5-31). Screws or ring shank nails with a minimum length of 25mm are suitable. Always observe a suitable distance to any UFH pipe when fixing the panels to the deck to avoid damaging the pipe.

The REHAU pipe identification tape must be fitted onto the ply surface at least every 0.6m with the printed arrows in line with the installed UFH pipes (see Fig. 5.32). This allows for easy identification of UFH pipe location after the REHAU plywood is in place.

Accepted by NHBCPanels are laid following current industry guidelines and practises for structural plywood. No glueing required.To achieve full load bearing capacity during construction the panels only need to be fixed at each corner and every 1.1m along each edge.

- No floor covering is to be placed directly onto the REHAU Easy Panels. All floor coverings must be fitted onto REHAU plywood.

- When tiling onto the REHAU plywood it is the responsibility of the tiling contractor / fitter to seek assurance from the tile manufacturer or the tile association that the fitted deck and plywood is sufficient to support the installation of the tiles without suffering flexural damage

- Before any overlay finishes are fitted it is essential that the entire floor area is perfectly clean, flat and dry.

- All floor coverings should be installed to the relevant manufactures or professional association’s recommendations.

5.6 REHAU wall thermostats/remote sensors

5.6.1 REHAU wall thermostatThe REHAU wall thermostat senses the room temperature and in combination with the REHAU Easy Control automatically adjusts the flow of water into your REHAU floor heating system. Turning the thermostat clockwise will reduce the flow of water and will lower the room temperature, turning it anti-clockwise will increase the flow leading to a higher room temperature. The REHAU wall thermostat fixing bracket is suitable for installations into stud walls as well as block walls.

Frost protection mode maintaining the room temperature at approx. 6 °CComfort setting maintaining a comfortable temperature while saving energy

I Wall thermostat is switched off – Frost protection mode is disabled

For optimum and reliable operation position the wall thermostat away from:- direct sunlight or any heat sources, e.g. television sets, etc- curtains, panelling or other objects which can block the air flow- At the end of the heating season turn the wall thermostat fully anti-clockwise.

This opens the connected REHAU Easy Control unit fully and ensures it does not get blocked through any dirt particles in the heating system.

The capillary tube connecting the wall thermostat to the REHAU Easy Control unit must not be- kinked or damaged in any way- installed directly onto, over or close to any heating pipes, radiators or any other

heat sources as this will have a negative effect on the operation of the system.Ensure the fixing bracket is fixed securely and level as otherwise the wall thermostat will not sit level against the wall.

Fig. 5-30 REHAU plywood

Fig. 5-31 Laying REHAU plywood

Fig. 5-33 REHAU wall thermostat

Fig. 5-34 REHAU fixing bracket for Wall

Fig. 5-32 Identification tape

26

Step 1:Install the fixing bracket for the wall thermostat in a suitable wall position making sure the selected routing for the capillary tube from the bracket centre to the corresponding REHAU Easy Control unit does not exceed the maximum reach of the capillary tube (Fig. 5-35 & 5-36).

Step 2:Secure the REHAU corrugated sleeve for 16mm pipes into place making sure it is not kinked and there are no sharp bends as the capillary actuator has to travel through this sleeve.

Step 3:With the REHAU corrugated sleeve secured into place attach it to the wall thermostat fixing bracket using cable ties so that the sleeve ends directly behind the centre hole (Fig. 5-37 & 5.-38).

- Use REHAU bend formers to create smooth and trouble free bends- Insert a draw wire (can be a length of single flex cable, string or similar) into

the full length of the corrugated sleeve to assist with the installation of the capillary tube after plastering.

The following steps are to be carried out during the 2nd fix of the building construction. To continue the following must be in place:- REHAU UFH floor systems, RAUTHERM universal pipe and REHAU Easy

Control units have been fully fitted and a pressure test has been successfully completed

- Plasterboards/render is in place and openings have been created in the designated positions for the wall thermostat

- Ensure installed conduits are free of any debris and easily accessible

Step 4:

Fig. 5-39 Removing plastic housing

Remove the plastic housing from the actuator end of the capillary tube (Fig. 5-39) by:- moving the lose chrome nut back onto the capillary tube and free of the

plastic housing- unscrewing the plastic end plug and- carefully pulling the actuator out of the plastic housing and its casing - slide the chrome nut and plastic end plug off.

Step 5:At the wall position of the thermostat attach the metal end of the capillary tube carefully but securely to the draw wire.

Step 6:Starting from this position feed the capillary tube into the corrugated sleeve towards the corresponding REHAU Easy Control by gently pulling the draw wire and taking care not to kink or damage the capillary tube (Fig. 5-40).

Step 7:Secure the wall thermostat into place with the two M3.5mm screws supplied with the fixing bracket ensuring the arrow on the square plate of the thermostat is facing upwards. With the indicator on the thermostat frame facing upwards, push the frame onto the thermostat until it clicks into place (Fig. 5-41).

The provided screws are intended for installations onto single sheet of plasterboard. For thicker coverings, extra long standard electrical screws of M3.5mm can be used.

Fig. 5-35 Position fixing bracket

Fig. 5-36 Installing fixing bracket

Fig. 5-37 Attaching sleeve Fig. 5-38 Securing sleeve

1

1 42 53 6

23 4

5

6

Chrome nut

Plastic housing

Actuator casing

Actuator

Plastic end plug

Capillary tube

Fig. 5-40 Installing capillary tube

Fig. 5-41 Securing thermostat

27

Step 8:Reattach the previously removed plastic housing of the actuator. Follow step 4 above in reverse order taking care to slide the freely moving chrome nut onto the capillary tube first.

Step 9:Connect the actuator onto the REHAU Easy Control and tighten the freely moving chrome nut onto the control body (Fig. 5-42)

Turn the wall thermostat fully clockwise to assist in tightening the actuator onto the main body.

Use a hex spanner 30mm or 1 ¼" AF to secure the chrome nut into place.

Health and safety caution The capillary tube contains ethyl acetate. Please carefully read the data sheet provided with the wall thermostat.

5.6.2 REHAU remote sensorThe REHAU remote sensor with 2m capillary tube in combination with the REHAU Easy Control automatically regulates the flow of water into your REHAU floor heating system. It is typically used in areas where the set point does not need to be changed frequently. Turning the thermostatic head clockwise will reduce the flow of water and will lower the room temperature, turning it anti-clockwise will increase the flow leading to a higher room temperature.

Frost protection mode maintaining the room temperature at approx. 6 °CComfort setting maintaining a comfortable temperature while saving energy

0 Wall thermostat is switched off – Frost protection mode is disabled

For optimum and reliable operation position the sensor element away from:- direct sunlight or any heat sources, e.g. television sets, etc- curtains, panelling or other objects which can block the air flow- At the end of the heating season turn the thermostatic head fully anti-

clockwise. This opens the connected REHAU Easy Control unit fully and ensures it does not get blocked through any dirt particles in the heating system

The capillary tube connecting the remote sensor to the REHAU Easy Control unit must not be- kinked or damaged in any way- installed directly onto, over or close to any heating pipes, radiators or any other

heat sources as this will have a negative effect on the operation of the system.

Step 1:Identify and mark a suitable wall position for the sensor element making sure the selected routing for the capillary tube back to the corresponding REHAU Easy Control does not exceed the maximum reach of the capillary tube.

Step 2:Secure the REHAU corrugated sleeve for 16mm pipes into place making sure it is not kinked and there are no sharp bends as the sensor element has to be travel through this sleeve.

- Use REHAU bend formers to create smooth and trouble free bends- Insert a draw wire (can be a length of single flex cable, string or similar) into

the full length of the corrugated sleeve to assist with the installation of the capillary tube after plastering.

The following steps are to be carried out during the 2nd fix of the building construction. To continue the following must be in place:- REHAU UFH floor systems and RAUTHERM universal pipe and REHAU Easy

Control unit have been fully fitted and a pressure test has been successfully completed

- Plasterboards/render is in place and openings have been created in the designated positions for the remote sensor

- Ensure installed conduits are free of any debris and easily accessible

Step 3:Starting at the REHAU Easy Control and using a draw wire feed the sensor element into the corrugated sleeve towards the final wall position taking care not to kink or damage the capillary tube.

Step 4:Unclip the cover from base of the provided bracket for the sensor element and fix the base onto the wall using the self adhesive tape on the back or the provided screws. Make sure to cover the hole where the sensor element emerges from behind the plasterboard.

Step 5:Snap the sensor element into the base taking care not to kink the capillary tube and re-attach the cover onto the base (Fig. 5-44).

Fig. 5-43 REHAU remote sensor

Fig. 5-42 Attach to REHAU Easy Control

Fig. 5-44 Fitting casing around sensor

element

28

Step 6:Holding the lower part, turn the thermostatic head fully anticlockwise up to mark 6 and align the lose chrome nut with the matching interface on the REHAU Easy Control unit. Ensure the pointer on the lower half of the thermostatic head is facing into the room. Then tighten the chrome nut moderately into place using 30mm spanner if needed (Fig. 5-45).

Step 7:Check function by turning the thermostatic head fully clockwise. The REHAU Easy Control should close.

Health and safety caution The capillary tube contains ethyl acetate. Please carefully read the data sheet provided with the remote sensor.

5.6.3 REHAU wall access panel

The following steps are to be carried out during the 2nd fix of the building construction. To continue the following must be in place: - REHAU Easy Control unit is fitted in place- Plasterboards/render is in place and- REHAU Easy Control units are in place

Step 1:Prepare a 157mm by 202mm hole in the dry-line material in front of the REHAU Easy Control (Fig. 5-46).

Step 2:Run a bead of a suitable adhesive all around the back edge of the frame.

Step 3:With the door securely fastened within the frame, insert the whole panel into the previously prepared hole and press firmly against the surface of the wall. Remove any excess adhesive which has seeped from behind the frame and leave to set.

- Lightweight panel.-Door can be completely removed for easy and convenient access-Panel can be painted or wall papered over

5.6.4 REHAU NEA HTREHAU proprietary heating thermostat with stylish design and illuminated LCD display showing current time and temperature. Used in conjunction with REHAU 2-port zone valve to achieve time & temperature control per heating zone in accordance with Building Regulations.- Three button control with valve

exercise and frost protection.- Operating modes: Automatic, standard, comfort and permanent off.- Three heating programmes per day and additional party/holiday mode.

Fig. 5-48 Unsuitable positions for NEA HT

All Information given in this publication in relation to the NEA HT is only an overview and must always be read in conjunction with the installation and user instructions provided with the NEA HT itself.

Fig. 5-49 Electrical connections to NEA HT, 230V

7 m

m*

60 mm

19 m

m

75 mm

88 mm

Step 1:Mark and mount the rear case of the NEA HT to the wall. The NEA HT is suitable for wall boxes with a centre hole distance of 60 mm Fig. 5-49.

Fig. 5-45 Pointer facing into room Fig. 5-47 REHAU NEA HT, 230V

55mm

8mm

154mm

204mm

Fig. 5-46 Fitting REHAU wall access panel

29

Step 2:Strip back the 1.0mm² wires as shown and connect each to its corresponding terminal clamp as shown in Fig. 5-49.

Fig. 5-50 Permissible area for electric cable

20 m

m

25 m

m

For installations directly onto plasterboards without a wall box, please allow a vertical offset of 19mm between the centre of the rear case and the cable entry into the wall and ensure the wall penetration is sealed against unwanted thermal draughts. Ensure the cable is contained within the shaded area of the rear case, Fig. 5-50.

Step 3:Locate the front cover onto the rear case making sure the arrows are aligned to each other and using the hinged clips as guide gently push the front cover onto the rear base until the locking clip has fully engaged. Fig.; 5-51-5-53. Fig. 5-51 Align arrows on parts

Fig. 5-53 Gently push until locking clip

engages

Fig. 5-52 Use hinged clips as guide and

engage first

30

6 commissioning

6.1 Fill and flush

Required Equipment:- 2 x 1/2" hose union- 2 x 1/2" hosepipe of suitable length- 1 x pressure test pump with- 1/2" union nut connection hose- 1 x air vent key (radiator key)- 2 x 15m ballofix valve- 1 x 1" x 3/8" 10 bar pressure gauge

When filling, flushing & pressure testing the system in conditions where the temperature is or is likely to be cold enough to freeze, the system will require an anti-freeze solution adding during the filling flushing and pressure testing procedure.

Only Antifreeze suitable for inclusion with HVAC systems should be used and mixed in accordance with the manufactures instructions and recommendations.

6.1.1 No primary pipe work installed

Step 1:Check all connecting unions are tight and all air vents including the ones integrated into the REHAU Easy Control are closed.

Step 2:Connect the hose from the mains water supply to the primary flow inlet on the REHAU Easy Control and the second hose leading to a suitable drainage point to the primary return outlet (Fig. 6-1).

Step 3:Open the REHAU Easy Control by turning the orange cap fully anti-clockwise and check the isolating valve is fully open.

Step 4:Turn on the water supply and wait until it runs free of debris and clear (no bubbles) at the drain. Turn off the water supply and turning the orange cap fully clockwise close the REHAU Easy Control.

Step 5:Carry out steps 1 to 4 on all REHAU Easy Controls fitted with UFH pipes.

6.1.2 With primary pipework connected to the REHAU Easy Control units

Step 1:Check all connecting unions are tight and all air vents including the ones integrated into the REHAU Easy Control and any drain valves fitted to the primary pipe work are closed.

Step 2:Connect the hose from the mains water supply to a suitable valve and pressure assembly on the primary flow pipe of the primary pipe work. Fit the 2nd hose from a drain valve in the primary pipework to a suitable drain.

Step 3:Close all REHAU Easy Controls by turning the orange cap fully clockwise.

Step 4:With the primary drain valve closed, open the water supply valve and wait until the water stops running.

Step 5:Open the primary drain valve and wait until for the water to run free of debris and clear (no bubbles) at the drain.

Step 6:Check the primary pipe work for any leaks. Then close the primary drain valve.

Step 7:Close the first REHAU Easy Control on the ground floor by turning the orange cap fully clockwise. Open the air vents bleeding all air out of the UFH circuits. When water appears, open the REHAU Easy Control by turning the orange cap fully anti-clockwise to bleed the remaining air from the primary flow connection. When only water appears again at the air vents close the air vents and the REHAU Easy Control by turning the orange cap fully clockwise.

Step 8:Repeat step 7 on all REHAU Easy Controls on the ground floor before continuing on the upper floors and the complete systems has been filled and vented.

Step 9:Close the primary flow valve.

6.2 Pressure testing

6.2.1 General guidelines for pressure testing

The successful execution and documentation of a pressure test is a prere quisite for any warranty claims from the REHAU guarantee.

According to BS EN 1264 and other industry guides, a pressure test must be conducted on the completed but not yet concealed piping before commissioning.

Assessments of a system‘s leak-tightness cannot be made on the results of the pressure test (constant, decreasing, increasing) alone.- The leak-tightness of the system must always be confirmed with a visual

examination of unconcealed lines.- Micro leaks can only be detected through a visual examination (water outlet

or leak detection agent) at high pressure.

Subdividing the piping system into smaller test sections increases the detection accuracy.

Fig. 6-1 REHAU Easy Control

connections

Air Vent

BalancingScrew

IsolatingValve

UFH Flow

UFH Return

Primary FlowPrimary Return Primary FlowPrimary Return Primary FlowPrimary Return Primary FlowPrimary Return

BalancingScrew

IsolatingValve

Air Vent

UFH Flow


IsolatingValve

Air Vent

UFH Flow


IsolatingValve

Air Vent

UFH Flow

UFH Return

Primary Return Primary Flow

IsolatingValve

BalancingScrew

Air Vent

UFH Return

UFH Flow UFH Flow

UFH Return

IsolatingValve

BalancingScrew

Air Vent

UFH Flow

UFH Return

IsolatingValve

BalancingScrew

Air Vent

Primary FlowPrimary Return Primary FlowPrimary Return

UFH Flow

UFH Return

Air Vent

BalancingScrew

IsolatingValve

Primary FlowPrimary Return

31

6.2.2 Pressure testing the floor heating systems with water

Step 1:Connect the pressure testing device to the lowest point on the floor heating installation.

Step 2:Close all extraction points carefully.

Step 3:Ensure that the temperature remains as constant as possible during the pressure test.

Step 4:Prepare the pressure test record (Fig. 6-2) and note the system data.

Step 5:Note the test pressure in the protocol and obtain signatures from the company who carried out the test and the client / main contractor.

Step 6:Disconnect the pressure test equipment.

The pressure test can be heavily influenced by temperature fluctuations in the piping system, e.g. a temperature change of 10 K can cause a pressure change of 0.5 to 1 bar.

Due to the pipe material properties (e.g. pipe elongation when there is increased pressurisation), the pressure can fluctuate during the pressure test.

The test pressure as well as the pressure progression which occurs during testing do not permit any sufficient conclusions as to the leak-tightness of the system. For this reason, the entire floor heating installation, as required in the standards, must be visually checked for leaks.

32

Fig. 6-2 Pressure test certificate

1. Project Name ..................................................................................................................................................

2. Installation Date

Max. Operating Pressure ................................................................................................................

Max. Operating Temperature ................................................................................................................

Test Pressure: ................................................................................................................ Ambient Temperature: ................................................................................................................

3. Pressure Test Completed

a) Flush and fill the circuit .......................

b) Pressureise to 6 bar (or) 1.5 times operating pressure whichever is greater .......................

c) Pressure several times again in accordance with the pressure test diagram ....................... (Pipe expansion causes initial pressure loss) d) Test Period for 3 hours ....................... e) Pressure test is succesful, if-there are no leaks within the circuits

- pressure has not fallen by more than 0.1 bar per hour .......................

4. Confirmation

The Pressure Testting was carried out in accordance with the above recommendations.No leaks were deducted and no component showed a permanent deformation.

Location: ..........................................................................

Date: ..........................................................................

M & E Contractor/ Installer: ..........................................................................

6.2.3 Pressure test certificate

33

Freezing Conditions:As the system is handed over filled with water, the pipes will be damaged if they are exposed to freezing conditions. If there is any risk of freezing conditions before the system is in full operation, the M&E contractor must ensure that:- The complete system including all concealed circuits is protected from

freezing.- The complete system is drained and all circuits are cleared off water using

compressed air in accordance with current Health & Safety Guidance.- A suitable anti-freeze is present at the manufacturer’s recommended

concentration throughout the system.

6.3 System balancing

-Balancing follows industry guidelines for radiator systems.-REHAU design information includes balancing data.-Use REHAU setting tool (Art No.218960-001) for easier & quicker balancing

To balance the system the-energy source must be connected and operational-primary pipe work and UFH must have been pressure tested-screed floors must have completed their curing cycle.

Balancing is carried out by adjusting the balancing screw on the REHAU Easy Control to the required setting between 1 and 6 (Fig.6-3) using the setting tool.

The required setting can be found on the REHAU design for the project. Alternatively tables 6-1 and 6-2 can be used as a general guidance for typical balancing settings.

It may be necessary to repeat the air bleeding and balancing process after the system has been in operation for some time while the last air is driven out of the system. Check the pressure gauge on the energy source regularly.

Fig. 6-3 Balancing screw

REHAU Easy Control

Fig. 6-4 Pressure loss of REHAU Easy Control

REHAU Easy PanelActive area

Installed pipe metres

50 W/m² setting

60 W/m² setting

70 W/m² setting

5m² 40m 0.5 0.5 0.5

7m² 50m 0.7 0.7 0.7

8m² 60m 0.9 0.9 1.0

10m² 70m 1.1 1.2 1.3

11m² 80m 1.4 1.6 2.4

13m² 90m 1.8 5.1 Not recommended

14m² 100m 5.6 Not recommended Not recommended

Table. 6-1 Balancing Setting for REHAU Easy Control with REHAU Easy Panel

Note: Maximum 20kPa pressure drop over UFH pipe & REHAU Easy Control with single

loop and 7.5K difference between flow and return temperature

REHAU RAUFIX/TackerActive Area

Installed pipe metres

50 W/m² setting

60 W/m² setting

70 W/m² setting

7.5m² 30m 0.8 0.8 0.8

10m² 40m 1.1 1.1 1.1

12.5m² 50m 1.3 1.3 1.4

15m² 60m 1.5 1.6 1.7

17.5m² 70m 1.9 2.0 2.3

20m² 80m 2.4 3.0 4.9

22.5m² 90m 3.8 Fully open Not recommended

25m² 100m Fully Open Not recommended Not recommended

Table. 6-2 Balancing Setting for REHAU Easy Control with REHAU RAUFIX/Tacker

Note: Maximum 20kPa pressure drop over UFH pipe & REHAU Easy Control with single

loop and 7.5K difference between flow and return temperature incl. 10% downward loss

34

6.4 Programming NEA HT

6.4.1 Thermostat control and display Powering up for the first time

The room thermostat is powering up with the factory default settings. After a power failure the thermostat will continue the operation mode as it was before the power failure. This will be up to 15 hours if the unit has been fully powered for 24 hours.

Installers parameter settings and time switch programs are permanently stored on power failure.

Key assignmentDecrease temperature. Also back in menu settingsIncrease temperature. Also forward in menu settingsEnter / ExitFlashing symbols or numbers are changeable

LCD icon

Indicator Description ExplanationTemperature Shows the actual room (R) temperature or the set (S) point temperature.

The set point temperature is your required room temperatureR Room temperature The displayed temperature is the current room temperature

S Set point temperature The displayed temperature is the required room temperature

Heating active Heating mode is active

Normal mode Operation mode normal is active

Reduced mode Operation mode reduced is active

Time switch program The thermostat will automatically select operation mode normal andreduced based on the internal/external time switch

Lock mode Protect the room thermostat against unauthorized access

Time Time display. Also used for date display in settings

Party mode Party mode is active

Holiday mode Holiday mode is active

Day Displays current day

Time status Displays evening or morning (12h clock)

6.4.2 Adjusting set temperature Reducing set temperature

To view the set point temperature only press once (see information on next page).

6.4.3 Operational modesSelection - Standard thermostat

When the NEA is set to OFF there is automatic frost protection active. If the temperature falls below 5 ºC the heating valve will be activated.

If a time switch is activated and the clock is displayed then the change in set temperature is temporary. The set point will return to normal / reduced on next time switch program change. If the clock is not displayed, the target value change is permanent.

Auto - Standard thermostat

R

S

S

R

1

2

3

4

or

or

R

2

3

4

R

R

1

or

or

or

or

A

B

R

R

A

B

AM PM

1234567 R S F

R

A After power up, all LCD segments

are turned on for two seconds. B After initialization the room thermostat

will show the standard display.

+- PM

R

1 Normal operation: Default set point 22ºC 2 Reduced operation: Default set point 18ºC 3 Auto operation: Only with external time switch 4 Operational mode off (optional)

1 Normal operation: Default set point 22ºC 2 Reduced operation: Default set point 18ºC 3 Auto operation: Only with external time switch 4 Operational mode off (optional)

A Time switch program activ; normal modeB Time switch program activ; reduced mode

Fig. 6-5

Fig. 6-6

Fig. 6-8

Fig. 6-9

Fig. 6-10

Table. 6-3

Fig. 6-7

35

6.4.4 Display messages

Frost protection display will remain until any key is pressed.

6.4.5 General function information Valve protectionTo protect the valves the output is turned on for 5 minutes in every week. This function stops the valve from getting stuck due to long periods of inactivity.

Pulse width modulationRoom temperature control is achieved by opening and closing the circuit control valves for defined times. The opening time of the valves is determined by the required energy supply.

PI controlThe PI control adjusts the control signal gradually to the demand of the system, in order to optimise the control result. This optimization must be applied very cautiously in case of surface heating and cooling.

Cleaning your NEAOnly use a soft, dry, solvent-free cloth for cleaning.

A blown fuse can indicate an error within your system. Before replacing the fuse, the system must be checked by an authorized specialist.

R

A

B-D

6.4.6 Technical data

NEA HT 230 V

Operating voltage 230 V-AC +/- 10 %

Max. switch current 0.2 A*

Fuse 0.63 A T

Safety** Class II

Max no. of actuators 5 x 3 W

Degree of protection IP30

Mode of operation 1.Y

Degree of contamination 2

Rated impulse voltage 4 kV

Anfi freeze operation 5 °C

Valve protection function 5 min/week

Dimensions frontside 88 x 88 (mm)

Dimensions backside 75 x 75 (mm)

Depth 26 (mm)

Operating values 6 .... 37 °C

Storage temperature -20 to 60 °C

Ambient temperature 0 to 50 °C

Relative humidity Max. 80 %, non condensing

Table. 6-4

* Resistive load

** Following proper installation, the requirements of the protective class will be met.

*** For power supply use a SELV-transformer.

A Frost protection is active B Er 4 – Room temperature out of sensor range C Er 5 – Interruption of room temperature probe D Er 6 – Short circuit of room temperature probe

Fig. 6-11

36

7 dEsign

7.1 Design factors

Fig. 7-1 Temperature distribution radiator vs UFH

Underfloor heating works by circulating warm water through a network of cross-linked polyethylene pipes laid in the floors, gently spreading heat through the house. With traditional radiators, temperature variations can occur due to uneven radiator coverage. Not so with underfloor heating, as the pipe network covers the entire floor area for even heat distribution throughout. REHAU follows the international design standards (BS EN 1264 & ISO 11855) for UFH systems which recommend a maximum floor surface temperature of 29ºC in all areas apart from bathrooms which are designed for 33ºC.

The key design factors to consider for an efficient UFH system are:

- Required Heat Loads & Associated Room Temperatures For new build homes these typically range from 45W/m2 up to 60W/m2 at room temperatures of 20ºC. The more accurate these are calculated the better the UFH system performs and the more cost effective it will be.

- Available Floor Area to Activate This is an important value as it has a direct effect on the required heating water temperature running through the pipes. The more floor area is available the more energy efficient the system can be designed. Typical rooms with reduced UFH area are bathrooms and kitchens.

- Floor Covering These have probably the biggest impact on the system design overall. The better they conduct heat, the more responsive the system is and the lower the necessary heating water temperature. UFH designs can of course be adapted to deal with every type of floor covering and a low conductive covering can be overcome with a higher water temperature. Care must be taken with some wood flooring and vinyl products where manufacturers sometimes specify a maximum surface temperature.

- Energy Source & Available water temperature The generated water temperature has a direct impact on the required flow rates and achievable heating outputs. It can also affect the hydraulic layout of the primary pipe work if a minimum flow rate is required. As is the case for floor coverings, the UFH design can be adapted to suit almost any energy source.

Design factor Impact on

Heat loads increase Water temperature increase

Room temperature. decrease Heat loads decrease

Floor area decrease Water temperature increase

Floor covering conductive decrease Water temperature increase

Available water temperature decrease Output Flow Rate

decrease increase

Table. 7-1 Key design factors and their impact

7.2 Typical outputs

The international design standards (BS EN 1264 & ISO 11855) for UFH systems recommend a maximum temperature difference of 9ºC between the heated floor surface and the room temperature. As a result the achievable output is 100 W/m2 for most areas once the system has stabilised and is operating at its design point. It should be mentioned that this is an imposed comfort limit and not a true limit of what the UFH system is able to deliver. The higher the floor surface temperature is selected in the design phase, the higher the resulting output.

Both design standards also provide calculation methods for achievable outputs on the most commonly used UFH systems. These calculation methods have been used and tested over many decades and the standards do provide generic tables for many design parameters which are used by many UFH system providers. Applied to wet systems, i.e. screed systems, these generic tables are accurate enough and the calculated and actual outputs do match sufficiently accurate. The situation is different however for dry systems where the contact between pipes and the floor structure is less predictable than in screed. Calculated outputs may therefore show a much better performance than the UFH system can deliver in reality.

All REHAU UFH systems are therefore always independently tested by accredited bodies in regards to their actual performance. The obtained performance characteristics are then uploaded into our customised UFH specific design software to ensure the highest possible accuracy and reliability in design. Tables 7-2 and 7-3 show the typical outputs for the REHAU Easy Heat system range.

REHAU Easy PanelFloor Covering Tiles Laminate Thick Carpet

Flow

Te

mpe

ratu

re 45°C 56 W/m² 50 W/m² 41 W/m²

50°C 69 W/m² 61 W/m² 50 W/m²

55°C 73 W/m² 60 W/m²

60°C 69 W/m²

Table. 7-2 Typical outputs of REHAU Easy Panel (at 20º air temperature & 7.5K

temperature drop F&R)

REHAU RAUFIX and TackerFloor Covering Tiles Laminate Thick Carpet

Flow

Te

mpe

ratu

re 45°C 95 W/m² 74 W/m² 53 W/m²

50°C 117 W/m² 92 W/m² 66 W/m²

55°C 139 W/m² 109 W/m² 78 W/m²

60°C 161 W/m² 127 W/m² 91 W/m²

Table. 7-3 Typical outputs of REHAU RAUFIX/Tacker systems (at 20º air temperature &

7.5K temperature drop F&R) Note: Pink shaded outputs are not recommended and will

only be considered in designs if explicitly requested.

-REHAU designs are based on independently tested performance data.-REHAU designs carry independent PI insurance of £ 2Mio-REHAU designs are provided by experienced UFH designers

REHAU’s Central Design Office creates reliable and detailed designs on a daily basis helping our clients and their customers to get the best out of our systems. To create a detailed design a minimum amount of information is required which has been summarised in our UFH Design Request Forms. You can obtain these from our sales offices and our webpage www.rehau.co.uk/easyheat

15ºC

18ºC 18ºC

15ºC15ºC

35ºC

32ºC

26ºC29ºC23ºC

43ºC 20ºC

17ºC15ºC

18ºC

27ºC 27ºC27ºC

37

7.3 Laying patterns

The heating requirement for a room is met by using any of the following laying patterns. The temperature distribution within the room alone will be effected dependent on which pattern is used.

7.3.1 Reverse spiralREHAU Tacker REHAU RAUFIX

Application All installations except suspended floor

Pipe - Only 90º pipe bends - Less demand on pipe

Room geometry Suitable for any area

Temperature distribution

Table. 7-4

7.3.2 Double meanderREHAU Tacker REHAU RAUFIX

Application Large industrial installations

Pipe - 180º pipe returns demanding on pipe - Minimum bend radii to observe

Room geometry Suitable for large / industrial areas


Table. 7-5

7.3.3 Single meanderREHAU Tacker REHAU RAUFIX REHAU Easy Panel

Application Suspended floors

Pipe - 180º pipe returns demanding on pipe - Minimum bend radii to observe

Room geometry Suitable for any area


Table. 7-6

Fig. 7-2 Reverse Spiral

Fig. 7-3 Double Meander

Fig. 7-4 Single Meander

38

8 stAndARds & gUidElinEs

Observe all applicable national and international regulations relating to laying, installation, safety and the prevention of accidents when installing pipe systems as well as the instructions in this technical information. Also adhere to the applicable laws, standards, guidelines, regulations (e.g. BS, DIN, EN, ISO, DVGW, TRGI, VDE and VDI) as well as the regulations on the protection of the environment, the regulations of the Employer’s Liability Insurance Associations and regulations of the public utilities companies.

Areas of application not covered in this technical information (special applications) require consultation with our technical applications department. Please contact your REHAU sales office for more detailed advice. The planning and assembly instructions relate directly to the corresponding REHAU product. Extracts of generally applicable standards or regulations are referred to.

Please ensure that the guidelines, standards and regulations are the valid issue in each case. More specific standards, regulations and directives relating to the planning, installation and operation of drinking water and heating systems or systems for building services must also be observed and do not form part of this technical information.

The technical information refers to the standards, regulations and guidelines(the current status is always valid):

BS EN ISO 15875Plastics piping systems for hot and cold water installations – Crosslinked polyethylene (PE-X)

DIN 16892Cross-linked high-density polyethylene (PE-X) pipes - General quality requirements, testing

DIN 16893Cross-linked high-density polyethylene (PE-X) pipes - Dimensions

DIN 4726Warm water surface heating systems and radiator connecting systems – Plastics piping systems and multi layer piping systems

BS EN 1264 Water based surface embedded heating and cooling systems Floor heating:

ISO 11855 Building Environment design - Design, dimensioning, installation and control of embedded radiant heating and cooling systems

BS EN 1990 Eurocode: Basis of structural design

BS EN 1991-1 Eurocode 1: Actions on structures

BS EN 1992-1 Eurocode 2: Actions on structures

BS EN 12871 Wood-based panels. Performance specifications and requirements for load bearing boards for use in floors, walls and roofs

EN 13986-2004 Typical performance characteristics wood based panels

EN-312-2003 Particleboard specification

BS EN 636 Plywood Specifications

BS EN 789 Timber structures. Test methods. Determination of mechanical properties of wood based panels

BS 8204-1:2003+A1:2009. Screeds, bases and in situ floorings. Concrete bases and cementitious levelling screeds to receive floorings. Code of practice

BS 8204-7:2003. Screeds, bases and in-situ floorings. Pumpable self-smoothing screeds. Code of practice

DIN 18560 Parts 1-7 and screed manufacturer's guidelines

BS EN 13163 Thermal insulation products for buildings

BS EN 13163 to DIN EN 13171 Thermal insulation products for buildings

BS EN 16313 Connections for heating and cooling appliances - detachable connection with outside threaded pipe G3/4" and inside cone.

BS 5449 Forced circulation hot water systems.

BS 7593 Treatment of water in domestic hot water central heating systems.

BS 5546 Installation of hot water supplies for domestic purposes.

BS EN 806 Specifications for installations inside buildings conveying water for human consumption.

BS 8558 Guide to the design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. Complementary guidance to BS EN 806

EN 15975 Security of drinking water supply

BSRIA Guide BG/2011 Underfloor Heating and Cooling

39

www.rehau.co.uk/easyheat 890618 EN 07.2014

contAct Us

Follow REHAU Easy Heat

UK & IRELAND SALES OFFICESSlough, Units 5 J & K, Langley Business Centre, Station Road, Langley, Slough SL3 8DS Phone: 01753 588500 Fax: 01753 588501 Glasgow, Phoenix House, Phoenix Crescent, Strathclyde Business Park, Bellshill, North Lanarkshire ML4 3NJ Phone: 01698 503700 Fax: 01698 503701

Our verbal and written application engineering advice is based upon experience and the best of our knowledge. However it is to be regarded as non-binding information. Working conditions and use under conditions for which the product was not intended and over which we have no influence exclude any claim resulting from our information. We recommend that a suitable check is made as to whether the REHAU product is suitable for the envisaged purpose. Application, use and processing of the products is carried out beyond the scope of our control and are therefore carried out exclusively at your own responsibility. If liability should still apply, then this is restricted, in the case of all damage, the value of the goods supplied by us and used by you. Our warranty applies to the consistent quality of our products as per our specification and in accordance with our general terms and conditions of delivery and payment. This document is protected by copyright. All rights based on this are reserved. No part of this publication may be translated, reproduced or transmitted in any form or by any similar means, electronic or mechanical, photocopying, recording or otherwise, or stored in a data retrieval system.

Documents

REHAU Easy Heat Installation Manual September 2014