Nu-Heat Install Manual PDF

Combined plumbingV4 Sept07:Layout 1
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warm water underfloor heating

installation manual
design
innovation
expertise
service
v4-sept 07
Nu-Heat
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Introduction
System Ref:
installation manual for nu-heat warm water underfloor heating

with fastflo tubing and optiflo control with a combination boiler,
user-supplied cylinder or energymaster cylinder
It is a condition of the warranty that the Certificate of Installation and

Commissioning application form is completed and returned to Nu-Heat
once the system is fully commissioned.
This set of manuals gives all the information needed to install your Nu-Heat warm
water underfloor heating system. In order for the process to be achieved quickly and
easily the principle of underfloor heating should be understood.
The following pages have comprehensive diagrams showing the purpose of each
system component and its position in the overall scheme. Parts shown in colour are
supplied by Nu-Heat and those shown in outline are generally supplied by others;
for example if a traditional radiator system is fitted alongside the underfloor heating,
control of the radiators is via a programmable room thermostat or timeclock with
individual thermostatic radiator valves as required. These parts are not supplied
by Nu-Heat.
System specification and electrical wiring details are supplied in the separate
manuals in this folder.
The boiler heat requirement for your underfloor heating system is noted on the
system design supplied together with the number and lengths of tubing coils and
their spacings for each individual room zone. The boiler should be chosen to match
the total load for the property.
Attention to the advice given in this manual will help to ensure a trouble-free and
effective installation. The requirements of the relevant British Standards, Water
Bye-laws and other regulations should always be met.
If there is any aspect of the installation that you do not understand, please contact
Nu-Heat Customer Support, quoting your system reference number, for advice.
In line with the company policy of product development, Nu-Heat reserves the right
to supply different components to those shown.
This manual is the copyright of Nu-Heat. All rights reserved. No part of this
publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means electronic, mechanical, photocopying, recording or
otherwise without prior written permission of Nu-Heat.
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Contents
Section
Contents
1.1
Checklist
1.2
Recommended installation sequence
1.3
System components:
Underfloor heating
Optional plumbing components
1.4
Optiflo manifolds
1.5
Pump Module:
Direct mounted pump module

Remote mounted pump module
1.6
Alupex
1.7
Connecting to the Optiflo Manifold
2.1
Installation details
2.2
Filling, flushing and pressure testing room zones
3.1
Installing the EnergyMaster cylinder:
Components
EnergyMaster2 cylinder
3.2
Filling the EnergyMaster cylinder
3.3
Temperature/pressure relief valve discharge
4.1
Filling the boiler and heating system pipework
Filling the boiler

Filling the heating system pipework with a
Direct Mounted Pump Module
Filling the heating system pipework with a

Remote Mounted Pump Module
4.2
Setting flow rates and Commissioning
5.1
Commissioning the EnergyMaster2 cylinder (where fitted)
6.1
Aquastar hot water loop
7.1
Problem solving Underfloor heating
7.2
Problem solving EnergyMaster2 cylinder
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1.1 Checklist
1.1 Checklist
Floor heights: Check that the height of the subfloor is correct for the depth of construction
needed to incorporate the underfloor heating. This is especially important if more than
one construction type or different floor finishes are used on the same floor.
Information on your specific A3 Floor Constructions is provided as part of the
A3 System Information.
Timber frame buildings: Check that the sole-plate depth will accommodate the appropriate
Nu-Heat floor construction. If the tubing is to be fitted from below in a suspended
timber first floor, any cross-blocking (noggins) must be reduced in height by 30mm to
allow the tubing to pass through and, where possible, any joist notching/service holes
must be drilled before laying the deck.
Floor insulation materials: Ground floor insulation must meet Building Regulations 2006,
Part L. A minimum requirement for ground floors is 75mm of PIR insulation (Celotex,
Kingspan, Ecotherm, Xtratherm), or 110mm of EPS (Jablite, etc). Advice on this should
be sought from your architect, builder or local authority planning department. For
floating floors Nu-Heat supplies EHDN grade polystyrene tracked to accept the heat
transfer plates and Fastflo tubing but this is not intended to meet Part L requirements
for ground floors. If you are installing from below in a suspended timber floor using
mineral wool insulation, certain floor constructions require a separate foil facing, which
is supplied by Nu-Heat (see the A3 Floor Construction detail at the beginning of this
folder). All other insulation materials are readily available from builders merchants.
Always read the floor construction information in the A3 System Information before
starting the tube installation. It is the responsibility of the customer to make sure that
insulation levels conform to the relevant British Standard and any other applicable
building code.
Mains water supply: Check that the performance of the mains supply matches the
requirements of the household. Refer to Section 4.3 for the requirements of the
EnergyMaster cylinder.
Fastflo tubing: The number and lengths of tubing coils and their spacings and flow rates
for each individual room zone are detailed on the A3 Tube Layout.
Avoiding damage to the tubing: If it is necessary to store the tubing, keep it dry, out of
direct sunlight and away from sharp objects or possible chemical spillage. Avoid any
soldering near Fastflo tubing as overheating may result in failure. Tubing that may
become frozen before or during installation or while the screed dries should have
anti-freeze added and be thoroughly flushed afterwards. Do not kink the tube by
over bending.
Boiler: The heat loading for your underfloor heating system is indicated on the A3 System
Information. Please refer to the boiler manufacturers recommendations for installing
and commissioning the boiler. Check the boiler installation requirements with the
manufacturer as in some cases a by-pass valve may be recommended between flow
and return pipework. Cooker-boilers may also have additional requirements; always
refer to manufacturers information. See you A3 System Information for advice on
expansion vessel sizing.
Insulation of pipework: The sensible use of insulation is recommended on the flow and
return pipework between the boiler, cylinder and Optiflo manifolds. Domestic hot
water pipework should also be insulated, particularly on a pumped loop. Ensure that
the incoming cold main is separated from any hot pipework to prevent heat transfer.
Taking delivery: Please check your delivery against the delivery note and report any
discrepancies within 7 days of receipt.
Warranty: In order to validate the warranty the Commissioning Checklist & Warranty
Application form in the Commissioning Pack attached to this manual must be
completed by the installer and returned to Nu-Heat.
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1.2 Recommended installation sequence

The general sequence of installation is as shown in this manual. Before starting check the
positions of the main components such as Optiflo manifolds and Pump Modules as agreed
at the system design stage and noted on the plans. Make sure that room dimensions and
joist spacings have not changed as this could affect the amounts of tube required. Full
dimensions of the components supplied are given in this manual, and suggested positions
for components can be found in the A3 System Information and A3 Manifold & Zone
Information.
1.
First-fix the main wiring. The positioning of the boiler, cylinder (if used), circulation
pump(s), thermostats and Optiflo wiring centres should be agreed between the
customer or architect, and the Nu-Heat designer. Please refer to the A3 System
Information and A3 Manifold & Zone Information for exact component locations
this can only be confirmed once the initial design work is complete.
Please refer to the separate electrical manual for detailed wiring diagrams.
2.
First fix the domestic services if they are to run beneath the floor insulation.
3.
Lay the floor insulation.
4.
Fix the Optiflo manifolds and circulation pump(s) in position. See Sections 1.4 and 1.5
for fixing instructions. See A3 System Information for locations. The manifolds are
reversible to allow right- or left-handed pipe connection.
5.
10mm Fastflo systems only First-fix the 18mm Alupex pipework between the Optiflo
manifolds and room distributor positions.
6.
Install and pressure test the underfloor heating tube.
7.
Fit the primary flow and return pipework between the boiler, cylinder (if used),
circulation pump(s), and the Optiflo manifolds. Follow the A3 System Information
at the beginning of this folder. Fit the boiler and cylinder if not done earlier.
8.
Fit the remaining hot and cold domestic water pipework. If an Aquastar hot water
loop has been specified, refer to the diagrams in Section 6 for details.
9.
Commissioning can only take place after all electrical installation has been completed
and checked by the electrician (see Electrical Manual).
1.2 Installation sequence
1.3 System components
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1.3 System components

Pump Module
This comprises of the pump and temperature blending valve. Depending on the system
design there may be Direct Mounted Pump Modules connected directly to the manifolds,
or centrally located Remote Mounted Pump Modules feeding multiple manifolds, or
a combination of these. Project-specific detail is contained in the A3 System Information.
The floor heating pump circulates the hot water from the boiler to the Optiflo manifold(s)
and around the floor heating tube. The temperature blending valve mixes hot boiler water
with the colder water returning from the underfloor heating to achieve the design
temperature, as set on the valve head.
Both assemblies can be connected left or right handed, see sections 1.5 for further details.
Optiflo Manifold may be connected either left or right-handed

The stainless-steel Optiflo manifolds are fed from the Pump Module. When hot water is
required by the underfloor heating system, a valve on the manifold opens and hot water
is pumped through to the tubing in the floor. The flow rate of the water is shown on a flow
gauge on the manifold. When the air temperature of each room reaches the required level,
the wall thermostat switches off its corresponding valve actuator on the manifold.
Manifolds are available with up to 12 ports. See Section 1.4.
18mm Alupex flow and return pipe (10mm & 14mm Fastflo systems only)
This larger, aluminium-cored pipe runs between the Optiflo manifold and the Fastflo tube
in the floor. It is important to label each length of pipe correctly with its zone number and
room name when it is connected to the manifold as they must be clearly identified in order
for the wiring to be successfully completed. See Section 1.6.
Distributor Module
10mm Fastflo
Distributor assemblies take water from the 18mm Alupex pipe connected to the Optiflo
manifold and direct it to 10mm Fastflo tubes in individual room zones. They can be joined
and fitted side-by-side to provide additional ports as specified in the A3 Tube Layout.
They are supplied with blanking plugs for unused ports. For screeded floors a moulded
box is provided to protect internal components. Further information can be found with
the A3 Floor Constructions.
14mm Fastflo
In certain floor constructions a zone may be fed by 18mm Alupex, and then Distributor
Modules can be used to feed two 14mm Fastflo pipes.
Cliptrack
Cliptrack is used to secure Fastflo tube in place on the floor. The tubing is held at the
correct spacings to ensure the room reaches its set temperature efficiently, note that these
spacings are detailed on the A3 Tube Layout drawings, and may vary from room to room.
Cliptrack can also be used when fitting tubing from below to first floor suspended timber
floors. Details are included in the A3 Floor Constructions at the front of this folder.
Note: Design of Cliptrack may vary according to floor type and pipe size.
14mm Fastflo & 16mm Alupex floor tube

The floor heating tube is connected to the flow and return ports on the Optiflo manifold.
The number of coils of tube and the spacing used in each zone are noted on the A3 Tube
Layout. Detailed instructions on how to lay the tubing in different A3 Floor Constructions
are included at the front of this folder.
10mm Fastflo floor tube

Fastflo-10 is connected to the flow and return ports of the distributors, which are fed by
18mm Alupex connected to the Optiflo manifold. The number of coils of tube and the
spacing used in each zone are noted on the A3 Tube Layout. Detailed instructions on
how to lay the tubing in different floor constructions are included at the front of this folder.
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1.3 System components Optional plumbing components

Aquastar Secondary Hot Water Loop
Hot water pump and timer
The hot water pump is connected to the return of the domestic hot water loop. It has
a timer to allow it to operate independently. It is important to connect the pump with the
arrow pointing in the direction of flow back to the cylinder.
Additional features include a water temperature control thermostat and non-return valve
with isolator. The pump will be sized depending on the length of the loop.
Hot water loop expansion vessel
The hot water loop expansion vessel, pressure gauge and pressure relief valve are
connected to the domestic hot water loop return. The 2-litre expansion vessel has a
pre-charged air pressure of 4 bar which must be checked and adjusted if necessary on
commissioning. There is a combined 10 bar pressure gauge and 6 bar pressure relief valve.
If the incoming mains pressure exceeds 3.5 bar, a pressure reducing valve the same size
as the incoming mains pipe must be fitted.
Drain valve
The drain valve is fitted on the return pipework of the hot water loop. It enables the system
to be drained for necessary maintenance. This valve is also used to purge air from the
return pipework when initial filling and system commissioning takes place.
For instructions on installing the Aquastar hot water loop see Section 6.
Optional heated towel rails

Heated towel rails
Heated towel rails can be installed on the hot water loop for both EnergyMaster and
user-supplied cylinders. This has the advantage of not having to run a separate circuit from
the heating system. To prevent corrosion by the mains water, any towel rail fitted must be
manufactured from non-ferrous material. They operate all year round whether the heating
is in use or not as they are entirely independent of the heating system.
Note:When towel rails are fitted to the hot water loop of an EnergyMaster cylinder the
return must be connected as shown on the plumbing schematic in the A3 System
Information.
A comprehensive range of suitable heated towel rails is available through Nu-Heat.
For further details talk to our Sales Team on 01404 549770 or visit www.towelrails.co.uk
For instructions on installing towel rails, see Section 6.
1.3 Optional components
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Optiflo manifolds are supplied boxed and ready assembled, except for the temperature
gauges which must be pushed into the pocket on each manifold rail. However you may
require to change the handing of the manifold, or orientate the outlets upwards.
Orientate manifold to suit installation
left-handed
Right- handed
1. Unscrew the manifold-rail mounting

clamps, turn the manifold to the correct
orientation and re-fit the mounting clamps.
Upside down.
3. Refit the boss on the front of the rail,

and the blanking screw on the back.
Refit the temperature gauges.
The Supply (flow) manifold must be the

rail with the flow gauges.
2. Remove the temperature gauges (these
are a press fit), unscrew the boss, and the
blanking screw on the reverse.
Note: The manifold brackets are designed

such that one rail is offset for the pipes to
pass behind it - the brackets should be
orientated to take account of the direction
of the pipes.
If the manifold is to be fed from a Direct Mounted Pump Module then this is connected to the captive nuts using the fibre washers
supplied to give a watertight seal. A proprietary sealing compound can be used in addition. With a Direct Mounted Pump Module the
shut-off valves are connected in the flow and return pipes on the boiler side of the Pump Module.
If the manifold(s) are to be fed from a Remote Mounted Pump Module then shut-off valves should be connected directly to the captive
nuts on the manifold, using the fibre washers supplied to give a watertight seal. A proprietary sealant may be used in addition to this.
The female end of the valve will accept the brass compression to male iron fitting that is supplied. The threaded connection and the
compression fitting should be made using either a proprietary sealing compound, or PTFE tape.
Connection valves and fittings are supplied in a separate kit.
Positioning
Place manifolds where they are easily accessible as settings may need to be changed. The
size of manifolds varies depending on the number of room zones being connected and the
cupboard or casing needs to be big enough to cater for this. See the A3 System Information
for detailed location.
28mm
200mm
600mm minimum to floor
1.4 Optiflo manifolds
1.4 Optiflo manifolds
Installation
1. Screw the manifold assembly firmly to
the wall by the fixing brackets. Position at
least 250mm from floor.
Note: If necessary, remove the lower
manifold to make access easier when
fitting the pipe to the upper manifold.
50mm
50mm
Number of ports:
Length in mm:
95mm
Length varies
2
10
11
12
195
245
295
345
395
445
495
545
595
645
695
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Depending on the design of system there may be Direct Mounted Pump Modules connected directly to the manifolds, or a centrally
located Remote Mounted Pump Module feeding multiple manifolds, or a combination of these. Refer to the A3 System Information
for system specific information.
270mm
200mm
Direct Mounted Pump Module
The Direct Mounted Pump Module connects

straight onto the manifold. Refer to the A3
System Information for manifold and Pump
Module positions.
58mm
140mm
100mm
Reversing the direction of the pump

As supplied the pump will connect to the left-hand end of the manifold. To connect the Pump Module to the right-hand end:
1. Reverse the manifold on its brackets,

and reverse the temperature gauges
see section 1.4 opposite
2. Remove the mixing valve castings from

the bottom of the pump by undoing the
pump nut. Take care not to lose or damage
the rubber washer.
3. The mixer casting will need the pump

connection to be moved to the opposite
side. Using a spanner unscrew the
blanking cap on the underside of the
mixer valve casting.
Note: this has a LEFT-HAND THREAD
rotate 180
5
4. Using a spanner unscrew the pump

connection from the top side of the mixer
valve casting.
Note: this has a LEFT-HAND THREAD
5. Replace the blanking cap and pump

connection such that the pump
connection is on top when the single
connection for the manifold cold return
is on the left, and the adjustment knob is
at the front (note that flow direction is
indicated by arrows on the casting).
6. Remount the casting onto the pump,

refitting the rubber washer. Loosen the
top casting and turn this to face left.
When attaching the manifold to the pump module make sure that the supplied fibre washer is fitted. A proprietary sealant may be used
in addition to this.
The boiler flow and return connections on the pump module will accept the 3/4 ball valves supplied with the pump module.
The threaded connection should be made using either a proprietary sealing compound, or PTFE tape.
3/4 male iron to 22mm compression fittings are supplied to connect the flow and return pipes to the ball valves.
1.5 Pump modules
1.5 Pump Modules
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1.5 Pump modules
1.5 Pump Modules continued

Remote Mounted Pump Module
Pump module
Manifold
UFH flow
Boiler flow
UFH return
Boiler return
The Remote Mounted Pump Module is located remotely from the

manifold(s). Refer to the A3 System Information for manifold
and Pump Module positions.
The Remote Mounted Pump Module should be screwed to the
wall using the holes provided in the backplate.
A separate manifold connection pack is supplied which contains
valves and compression fittings. The male end of these valve fits
onto the captive nut on the manifold rail, using the fibre washer
supplied to create a watertight seal. A proprietary sealant may
be used in addition to this.
The female end of the valve will accept the brass compression to
male iron fitting that is supplied. The threaded connection and
the compression fitting should be made using either a proprietary
sealing compound, or PTFE tape.
The Pump Module has 28mm stub ends to connect to your boiler,
and manifold supply pipework. These may be connected using
either compression, push-fit or soldered fittings.
Recommended pipe sizing to and from the Pump Module
are given on the A3 System Information at the beginning
of this folder.
Reversing the direction of the remote pump

As supplied the Pump Module will receive the boiler flow and return from the left hand side, feeding the manifold(s) from the
right-hand side. It may be reversed by rotating the Pump Module through 180 before fixing in position.
UFH flow
Boiler
return
UFH return
Boiler flow
1
Note: At some point between the Pump

Module and the Optiflo manifold, the pipe
work must cross over to ensure that the
flow from the boiler connects to the flow
(upper) manifold and the boiler return
pipework connects to the return (lower)
manifold as shown.
rotate through 180
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1.6 Alupex
For systems using 10mm Fastflo tube, as well as some 14mm constructions, 18mm Alupex
pipe is provided for the flow and return pipework between the Optiflo manifolds and the
distributors in each zone.
14mm
distributor
module
18mm pipe fitting
The 18mm pipe should follow the easiest, most direct route. Where appropriate it should
be tracked into the insulation below the Fastflo tube using a router.
In certain A3 Floor Constructions clips are provided to secure the Alupex onto the
insulation. See also the A3 Floor Construction detail at the front of this folder.
Universal joiner
1.6 Alupex
18mm Alupex
Port splitter
This 18mm pipe can be carefully bent to form curves of approximately 100mm radius.
If right-angle elbows are required for tight turns, they can be purchased from Nu-Heat.
In 14mm systems a Distributor Module is sometimes used to connect from 18mm Alupex
to a pair of 14mm Fastflo pipes. Refer to the A3 Floor Constructions in the A3 System
Information for details.
For systems using only plastic(PeX) pipe, if this is to be routed through a stud wall then a
metallic tape should be located along the same route to make the pipe traceable. The tape
is best attached to the wall behind the pipe, rather than to the pipe itself, as some adhesives
affect the material properties of the pipe.
14mm pipe fitting
14mm Fastflo
1. Re-shape the ends of the pipe using

the calibration tool, opening out the ends
to allow fitting of the insert without
displacing the O-rings.
14mm Pex pipe with 12mm internal diameter
or
16mm Alupex pipe with1
2mm internal diameter
Note: Do not forget to place the nut

and olive over the pipe before fitting
the insert.
or
18mm Alupex pipe with
14mm internal diameter
calibration tool
Important!
PE
Dining Room
Zone 3
ER
K
AR
M
Dining Room
Zone 3
2
connect
2. Connect the flow pipe to the ports

on the upper manifold with the fittings
supplied the lower manifold may be
removed to make this easier.
He
u-
at
3. Important: It is critical to clearly mark

each pipe with its correct zone number
and room name with the marker pen
provided. The electrician will need this
information to wire the system correctly.
See the A3 Manifold & Zone Information
for more information.
4. Re-attach the lower manifold to the

fixing brackets (if removed).
5. Connect the return pipe to the correct
ports in the same way.
1.7 Connect to the manifold
1.7 Connecting to the Optiflo Manifold
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2.1 Installation details
2.1 Installation details

For installation details referring to the specific floor types and underfloor heating tube
layouts within your property, please refer to the A3 Tube Layouts and A3 Floor
Constructions at the beginning of this folder.
2.2 Filling, flushing and pressure testing room zones

Pressure testing room zones
Zones must be pressure tested prior to screeding or covering the tube. Follow the full
procedure for each zone and for each manifold assembly.
Note: Any unused ports on the Optiflo manifold can be isolated for future use by using
the blue cap to close the return and the screwing down the flow adjustment on the
supply manifold.
Filling, flushing and pressure testing
1. Close the isolating ball valves that are

either connected directly to the manifold,
or connected just before the Direct
Mounted Pump Module
2. Isolate all zones by screwing down all

the blue protection caps hand tight.
3. Fully open all the flow adjusters on the

supply (top) manifold by lifting the red
locking collar which may then be used to
turn the black collar fully anti-clockwise.
open valve
4
4. Remove the blanking cap from the

filling valve on the flow (upper) manifold.
Fit the hose connection nozzle (from the
tools and accessories pack), and connect a
suitable hose from the mains water supply.
Open the filling valve using key on the
blanking cap.
5. Similarly fix a suitable hose to the drain
valve on the return (lower) manifold.
6. Fully loosen the protection cap from the

first zone to be filled.
7. Open the tap on the mains water supply

and open the drain valve on the return
(lower) manifold using key on the blanking
cap.
8. Run the water until all air is expelled
from the pipe. This will take approx.
5 minutes.
Tip: If the outflow is run into a bucket then
air bubbles will be detectable.
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open
9
5 6
1 2
3 4
10
close
12
close
9. Open the next zone.
12. Close the drain valve on the return

(lower) manifold.
10. Close the flushed zone.

11. Repeat steps 8 10 for all zones on
each manifold.
5 6
1 2
3 4
14
close
5 6
1 2
3 4
16
release
pressure
14. When the correct pressure is reached,
close the filling valve.
15. All zones are now fully pressurised
and should be left for at least 8 hours.
Due to expansion and air temperature
variations, a pressure drop of up to
approximately 0.5 bar may occur. If
greater pressure drops are experienced,
thoroughly check all pipes and joints for
evidence of water loss. If none is found,
there may still be air in the system and the
filling and flushing procedure should be
repeated.
16. After testing, reduce the pressure to

1 bar-static by releasing the water from the
drain valve on the return(lower) manifold.
Note: The floor heating tube must be left
under pressure whilst floors are screeded.
1 bar is sufficient.
13. Allow the pressure to rise to a

maximum of 6 bar
2.2 Fill/flush/pressure test
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3.1 EnergyMaster cylinder
3.1 Installing the EnergyMaster Cylinder

Components
EnergyMaster cylinder
Please refer to your A3 System Design for your specific plumbing schematic.
The EnergyMaster cylinder stores water for both the floor heating and the production of
domestic hot water. If the temperature of the water in the cylinder falls below the level set
on the cylinder thermostat, the boiler is turned on and hot water is circulated into the body
of the cylinder to replenish the store.
In larger properties either a larger cylinder, or twin cylinders may be recommended to

ensure an adequate supply of hot water.
TPR15
3
4
The positioning of the cylinder within the property will have been agreed after consultation
with the Nu-Heat designer. Detailed dimensions, fixing and connections are given in this
section.
1. Automatic air vent
2. Temperature / Pressure relief valve (factory fitted)

3. Chrome pipework assembly (trim to length)
7
8
4. Hot water blending valve

5. Shock arrestor connection/connection point for hot water loop return when no towel
rails are fitted
6. Flow switch
7. Cylinder thermostat
8. 3kW immersion heater
If the EnergyMaster cylinder is used without an Aquastar hot water loop then a shock
arrestor is supplied. This vessel absorbs the small amount of expansion in the domestic hot
water pipework when the system is hot and must be checked and set to 4-bar when the
system is cold, at commissioning stage.
Auto air vent operation and maintenance

For rapid venting when filling the cylinder remove both caps and depress the valve under
the red cap with a screwdriver. Replace the red cap when the system is full.
Rapid vent
screw
Bleed
screw
During normal operation the cylinder is vented by leaving the black bleed cap loose, this
allows stray pockets of air to escape automatically and should be checked regularly.
Important: to prevent cylinder collapse when draining down the system ensure the rapid
venting valve is depressed or the air vent connections loosened.
Temperature/pressure relief valve

If, in the unlikely event of failure of all other safety devices, the cylinder reaches high
pressure or temperature then water will be discharged by this valve. The outlet from this
valve should be safely taken to waste (see information in Section 3.2). The valve should be
manually operated during the annual servicing by turning the black knob in order to check
that it is free to function.
TPR15
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Shunt pump, valves and bends

Mounted on the EnergyMaster cylinder and controlled by the flow switch, this pump
circulates stored boiler water through the domestic hot water heat exchanger giving
mains-pressure hot water on demand. Important: Arrow indicates direction of water flow.
Flow switch
The flow switch detects the flow of water into the EnergyMaster cylinders internal heat
exchanger. The switch operates the shunt pump, ensuring that the heat exchanger can
work at its maximum capacity. The flow switch must be fitted in the orientation shown,
with the arrow pointing upwards.
Isolating valve and strainer

The in-line 22mm isolating ball valve with filter is fitted on the cold mains supply to the
EnergyMaster cylinder. It prevents grit getting into the cylinder and enables the cold water
supply to the cylinder to be shut off if necessary. It must be fitted with the trap below the
pipework. Restrict the incoming mains cold water flow rate to between 22 and 27
litres/min. for 210 litre cylinders, 36 and 40 litres/min. for 300 litre cylinders and between
54 and 63 litres/min. in total.
Cylinder zone valve

The zone valve controls the flow of water from the boiler to the cylinder. It opens when the
cylinder thermostat calls for heat. Ensure the valve is positioned on the boiler flow pipe as
shown in the A3 System Information. This valve must be fitted in all cases as it acts as
protection against overheating.
2
3
1
4
Expansion vessel and filling loop assembly

The expansion vessel forms part of the filling loop assembly. It accommodates boiler and
cylinder water expansion when the system is hot. Use in addition to any internal systemboiler vessels to accommodate the additional expansion of the EnergyMaster cylinder
water volume. It is important to note: before fitting the expansion vessel the air pressure
must be reset. Refer to A3 System Information.
1
1. Connection to boiler primaries

2. Pressure gauge
2
3
1
4
3. Pressure relief valve

4. Discharge to waste
5. Non-return valve
6. Isolating valves (2)
7. 15mm cold mains in
8. 15mm Pressure reducing valve adjusted to 1-bar maximum fill pressure

9. Air valve connection (for charging and checking pre-charged air pressure)
9
10. Expansion vessel
10
7 8
21/9/07
15:33
Page 16
3.1 EnergyMaster2 cylinder

Performance (figures shown in brackets are for 300 litre cylinder)
The EnergyMaster cylinder is designed to provide a maximum flow rate of 26(40)l/min, raising mains cold water through 40C at full
duty.
Mains water supply
The cylinder should take its mains water feed before all other cold water draw-offs, above the stop cock. If the mains pressure exceeds
3.5-bar it should be limited to this figure by a pressure reducing valve (not supplied) equal to the size of the connecting pipework, fitted
after the incoming stopcock and before any draw-off points.
A mains water input of 2227 (3040) l/min (or double for dual cylinders) is required at minimum static pressure of 2-bar. Where the
supply is inadequate but the incoming mains pressure is over 2-bar it can be boosted with a purpose-designed accumulator vessel.
Please contact Nu-Heat for details.
Pipework
The minimum size of copper pipework to be used for mains water connections to and from the cylinder is 22mm for single cylinder and
28mm for dual cylinder systems and for the 300 litre cylinder.
Notes: If the EnergyMaster cylinder has to be drained, either depress the red capped fast-purge valve on the auto air vent or remove
the entire auto air vent. Failure to do this could result in major damage and collapse of the cylinder. Solar coil cylinders will have
additional connections for the solar coil.
EnergyMaster Cylinder capacity 210 (300) litres
Preferred width of cupboard 1185mm

2270mm for dual cylinder systems
Minimum cupboard depth 675 (800)mm
Cylinder weight when full 272 (400) kg

Cylinder weight when empty 62 (100) kg
Diameter 540 (600)mm

Minimum height of cupboard
Overall height
Cylinder height
TPR15
Boiler flow
28mm
Drain-off
Floor heating flow
28mm
Floor heating
return
28mm
1
/2
Approx. 1100 (1313)mm
28mm
200 (228)mm
260 (288)mm
Boiler return
Flow switch
mains cold water in
930 (1128)mm
22mm
22mm
Approx. 785 (843)mm
Shunt pump & valves
500 (528)mm
1625 (1816)mm
22mm
1508 (1751)mm
Shock arrestor connection
1320 (1538)mm
1635 (1880)mm
Domestic hot water out

(22mm connection)
21/9/07
15:33
Page 17
The pipe work that takes any discharge from the temperature/pressure relief valve should
be fitted in copper. A tundish is not a mandatory requirement, but may be fitted if desired.
In either case the outlet of the pipe should be taken to a safe place, as any water/steam
released is a scald hazard. Such a safe place would be below a fixed grate to a trapped
gully. Note that the discharge will be either very hot water or steam, that will cause damage
to certain plastics or asphalt, etc. The pipe work should be sized so as not to restrict the
discharge. The diameter should be at least as large as the outlet of the valve. If the length
of pipe is greater than 9m then the next size up is required (i.e if a 15mm (1/2) valve then
22mm pipe work), and if longer than 18m then two sizes larger, and so-on. Any bends and
elbows also present a pressure drop, and these must be accounted for by assigning an
equivalent pipe length as given in the table below.
1/2 Valve:
Pipe size (mm)
Max. pipe length based

on straight length (m)
Equivalent resistance
of bend or elbow (m)
15
0.8
22
18
1.0
28
27
1.4
The pipe should drop continuously away from the valve.

Note: If a tundish is fitted then the outflow from it should be made in the next largest size
from the inlet, again increasing the size for each additional 9m in length, including bend or
elbow equivalent length.
3.2 Temperature/pressure relief valve discharge
21/9/07
15:33
Page 18
3.3 Filling the EnergyMaster cylinder

The boiler filling loop can be used to fill the cylinder. Whilst filling the cylinder it
is important that the fast purge valve under the red cap of the Automatic Air Vent is
depressed. Alternatively the air vent may be removed until the cylinder is nearly full,
and then the fast purge should be used.
3.4 EnergyMaster hot water supply

Domestic hot water temperature blending valve
The domestic hot water blending valve should be fitted to the EnergyMaster cylinder. It is
supplied pre-set at 43C but if a different temperature is required the following procedure
should be followed:
Remove the screw securing the blue (or red on the 300 litre cylinder) knob to the valve.
Remove both the blue (red) knob and the locking ring.
Replace the blue (red) knob temporarily.
Open a tap and adjust the set temperature of the valve as required (anti clockwise to
increase and clockwise to decrease).
Domestic hot water temperature

blending valve (210 litre)
Remove the blue (red) knob and refit the locking ring.
Locate the tab on the inner face of the blue (red) knob into the retainer in the locking
collar and secure the knob with the socket screw.
Maintenance of the domestic hot water blending valve
The valve should be checked and cleaned annually. If the cylinders domestic hot water
pipe is hot and the blending valve outlet pipe cold it is possible that there is a build up of
scale within the valve. To strip down the valve and clean:
35
MIN
MAX
65
Drain the domestic hot water system.

Isolate the valve and remove the blue (red) knob and locking ring.
Unscrew the large hexagonal cap and slide out the interior parts of the valve. (Note the
orientation of the parts to aid reassembly.)
After cleaning and reassembling, the valve should be reset and tested.
Balancing domestic hot and cold water supplies
Balance the hot and cold water to all taps according to normal practice.
Limescale prevention
Important: In semi-hard and hard-water areas where typically CaCo3 exceeds 200ppm,
the incoming water should be treated appropriately. Where extreme water conditions exist
the use of a high pressure water softener is recommended. Please ensure the model
chosen will not give significant water pressure and flow rate drops. Contact the local water
authority for details.
Domestic hot water temperature

blending valve (300 litre)
21/9/07
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Page 19
4.1 Filling the system
4.1 Filling the boiler and heating system pipework

Filling the boiler
Fill the boiler via the boiler filling loop whilst venting the system and following the boiler
manufacturers instructions. The system should be cleansed and flushed in accordance with
BS7593:1992 to remove all flux residue and other debris.
Filling the heating system pipework with a Direct Mounted Pump Module
At the first manifold:
2
3
1
0
2 connect
fill the system

4
3
open
5 close
1
open
connect
1. Open the flow isolation valve.
2. Find the hose tails from the tools and

accessories pack and connect to the fill
and flush hoses.
3. Use the cap end to open the drain cock
on the flow (upper) manifold.
4. Fill the system via the boiler filling loop

and run water through until the flow from
the drain hose is free from air bubbles.
5. Close the boiler filling loop and drain
cock.
remove
7
connect
7
6 close
10
11
open
set
temperature
8 open
6 open
6. Shut the flow isolation valve and open

the return valve.
9. Repeat steps 4 and 5.

7. Remove the hose from the upper drain

cock and connect it to the return (lower)
drain cock.
on the return (lower) manifold.
11. The temperature control valve on the

pump module should be set to minimum.
12. Repeat steps 1 to 11 at each manifold

that is fitted with a Direct Mounted Pump
Module.
Note: The system cold working pressure
is 1.0 bar. When the system pressure
has been set, isolate the filling loop and
disconnect in accordance with water
authority regulations
21/9/07
15:33
Page 20
4.1 Filling the system
4.1 Filling the boiler and heating system pipework

Filling the heating system pipework with an Remote Mounted Pump Module
At the first manifold:
1
2 connect
open
3
open
2. Find the hose tails from the tools and

accessories pack and connect to the fill
and flush hoses.
remove
4. Remove the head from the blending

valve on the pump module.

on the flow (upper) manifold.
7 close
2
3
1
0
remove
fill the system

5
6 close
7 open
connect
8
9 open
5. Fill the system via the boiler filling loop

and run water through until the flow from
the drain hose is free from air bubbles.
7. Shut the flow isolation valve and open

the return valve.
8. Remove the hose from the upper drain

cock and connect it to the return (lower)
drain cock.
9. Open the drain cock on the return
(lower) manifold.
6. Close the boiler filling loop and drain

cock.
10. Repeat steps 5 and 6.

11
open
13
14
set to 0.5 bar
12 fit control valve
12. Fit the water control valve temperature

adjustment head and adjust to minimum.
13. Fix the temperature phial and capillary
tube to the pipe work on the underfloor
heating side of the pump, using aluminium
saddle piece and cable tie provided.
14. The differential bypass valve should
be set to 0.5 bar.
15. Repeat steps 1 to 12 at each manifold.

Note: The system cold working pressure
is 1.0 bar. When the system pressure has
been set, isolate the filling loop and
disconnect in accordance with water
authority regulations.
21/9/07
15:33
Page 21
Before starting check that:

1. The heating and hot water system is fully operational and the
boiler has been commissioned.
2. Screed floors have been left to thoroughly dry out. The drying
process depends on screed type and thickness, (please refer to
BS8204), but allow a minimum of four weeks. The floor heating
should not be used to accelerate the drying process.
3. All underfloor zones served by the manifold have been filled,
flushed and pressure tested. See Section 2.2.
4. The boiler and primary flow and return have been filled,
flushed, cleansed and vented. See Section 4.1.
5. All electrical work associated with the heating system is

complete and actuator heads are fitted. (where appropriate see
A3 Manifold & Zone Information for specific information)
6. The system static pressure is set at 1 bar when cold or
approximately 1.5 bar when hot.
7. The main manifold isolating valves are open.
8. All pipes entering the manifold assembly have been clearly
marked with their zone number and name as detailed on the
system design.
9. All actuators cables have been similarly labelled.
set to speed 3
Dining Room
Zone 3
To set the flow rates

1. Set the floor heating pump to speed 3
and start by turning up all the room
thermostats. Make sure all zones are
flowing. When a zone is open the blue
indicator on top of the actuator head
stands proud. There is a 3 minute delay
before the actuators open fully.
2. Each zone has a specific flow rate which

is detailed on the A3 Manifold & Zone
Information.
Starting with the zone needing the least
flow, lift the red locking collar around the
flow gauge, reverse it and use it to turn the
black nut. Turn the nut anti-clockwise to
increase the flow, or clockwise to decrease
the flow. Following the flushing procedure
the valves are likely to be fully open.
Replace the red locking collar.

Note: Flow rates detailed on the A3
Manifold and Zone Information sheet are
a minimum. The flow setting should be set
as close to this level as possible or slightly
above. Increasing the flow to one zone
may slightly decrease the flow to the
others and small adjustments may be
necessary.
3. Record the flow rates on the labels

provided.
It is essential that actuators and zone
pipes are correctly labelled. The room
thermostat must control the actuator on
the pipe serving that zone.
Zone:
Flow Rate l/ m :
Enter flow rate

on labels
4.2 Commissioning
4.2 Setting flow rates and Commissioning
21/9/07
15:33
Page 22
4.2 Commissioning
To set the temperature
verify
2
adjust
direct mounted
pump
1. Turn all the room thermostats up to a

high temperature. This will open all the
zone isolating actuator valves.
adjust
remote mounted
pump
2. Adjust the floor heating water

temperature control valves (found either
next to the manifold, or on to the Remote
Mounted Pump Module) to give the
correct flow temperature as detailed on
the A3 Manifold & Zone Information.
This temperature can be verified on the
gauge on the flow (top) rail of the
manifold(s). Final adjustments may be

necessary when the system is up to
operating temperature.
Note: For screed floors set the water
temperature at minimum for the first three
days, and then only increased by 5 on
each subsequent day.
5.1 Commissioning the EnergyMaster Cylinder (where fitted)

System Settings
2
Set cylinder thermostat to

65 70C maximum.
1. Boiler Thermostat set to a higher

temperature than the cylinder thermostat
(minimum 75C). Ensure the boiler output
rating is set to maximum. If resetting is
necessary, please refer to manufacturers
instructions.
3 Set floor heating

pumps to speed 3
4 Set cylinder shunt

pump to speed 2
2. Set the cylinder thermostat to 65C.

This can be increased to a maximum of
70C if necessary providing the boiler
thermostat is at least 10C higher.
5 Set boiler pump

to speed 3
3. set the cylinder shunt pump to speed 3.

4. Set the boiler pump to speed 3.
Note: When the system has been running for at least 60 minutes, the temperature difference between the flow and return pipework
at the boiler should be approximately 11C. If it is much higher than this, check that the boiler pump is set to speed 3, (if using
a system boiler the pump will be inside the boiler and may not be adjustable). If it remains high, please call Nu-Heat Customer Support
for advice.
4.2 Commissioning
Commissioning
The system must now be thoroughly checked in accordance with the Commissioning Checklist and Warranty Application
form in the Commissioning Pack. This must be fully completed during the commissioning process and returned to Nu-Heat
for registration.
No warranty can be issued without the return of the completed Commissioning Checklist to Nu-Heat.
Installing the inhibitor
As soon as the commissioning is completed an inhibitor must be introduced into the heating system. For continued long-term
protection the system inhibitor levels should be checked annually.
21/9/07
15:33
Page 23
6.1 Aquastar hot water loop
6.1 Aquastar hot water loop

The Aquastar2 instant hot water loop (or for larger systems, Aquastar3) may be used
with many modern hot water cylinders to give hot water at the taps without delay.
The hot water loop will remain hot as dictated by the timer settings. Hot water drawn
outside of the set times will take time to flow hot, as if the hot water loop were not
present. The Aquastar hot water loop provides the ideal basis for the connection of
towel rails throughout the house as very little extra plumbing is required. Heat for the
towel rails is drawn from the existing heat reservoir in the hot water cylinder, usually
without the need to bring on the boiler.
Notes:
The Aquastar hot water loop is only suitable for mains pressure hot water cylinders.
Check that the installation of a pumped hot water loop is consistent with local water
bye-laws.
Appearance of pumps may vary

Non-return
valve
Pump
12:00
Timeclock
As the towel rails are heated by mains water they must be non-ferrous to prevent
corrosion. The total output from all towel rails connected to the hot water loop must
not exceed 5000 watts. Please contact Nu-Heat if the total output will be greater.
Pipe stat
Discharge
Flush/drain
The temperature of the loop, and therefore of the towel rails, is thermostatically
controlled to prevent scalding. On the side of the Aquastar2 circulating pump there is
a thermostat or, on larger systems, there is a separate thermostat mounted on a nearby
pipe this should be set to approximately 1/3rd scale or 40C.
6.2 Planning and installing the

loop
Expansion
vessel
Larger systems have Aquastar
components supplied as separate items
Bathroom 1
Bathroom 2
out
For cylinder connection details refer to
cylinder manufacturer
return
Outlet balancing
valves
Pump
Radiator
lockshield
valves
Bathroom 3
Non-return
valve
(may be part
of pump)
Flush/
drain
Kitchen
Utility
Loop
balancing
valves
Discharge
Careful thought should be given to the layout of the hot water

loop and the fittings used on it. Flow pipework to bathrooms
should be sized according to the hot water requirements of the
household. Typically a small to medium sized installation will
require 22mm flow pipework, a large installation may require
28mm or greater. 15mm pipe may be used for the last 2 metres
where the pipe connects to the Aquastar2 pump (22mm for
Aquastar3). Individual hot water outlets should be fitted with
flow-limiting valves to prevent unnecessarily high water flow rates
affecting the water pressure at critical points such as shower
units. Towel rails must be fitted with lockshield valves for
balancing and isolation. Use only 15mm connections with control

valves. The towel rails can then be controlled individually by
using the lockshield valves in the same way as a traditional
radiator circuit. Fit a balancing valve or towel rail at the farthest
end of each loop. If bathrooms are to be connected to the hot
water loop in parallel, balancing valves must be fitted on each
leg so that balancing between bathrooms can be effective (see
illustration). The hot water flow and return pipes should be
insulated to prevent unwanted heatloss. This is particularly
important where hot pipes run alongside the supply pipes to
cold tap.
21/9/07
15:33
Page 24
7.1 Problem solving
7.1 Problem solving underfloor heating

Problem:
Electrical components not operating
Solution:
Please refer to the Electrical Checklist to confirm the system and system components are wired correctly.
If the component still fails to work it should be replaced.
Problem:
No flow rate at the Optiflo manifold
Solution:
Is there flow to any zone?

No
Check the pump and replace if faulty.
The air vent can be removed

to check impeller rotation
Yes
Are the actuators open?

No Check the actuator lead is properly connected to the Optiflo
wiring board.
Yes
The ufh tubes may be air-locked fill and flush the system again.
The ufh tubes may be wrongly connected, ie, flow to flow and
return to return with no circulation reconnect correctly.
The ufh tube may be kinked investigate and correct.
Problem:
Low flow rate on the Optiflo manifold
Solution:
Check the pump is set to speed 3 and is circulating in the correct direction as in Section 1.5.
Check the ufh tube for air locks, wrong connections or kinks as above.
Following adjustment, are the design flow rates correct for the majority of zones?
No Please contact Nu-Heat Technical.
Yes
The pump should be

set to speed 3
Turn off all the zones, turn on one low flow zone.
Can the correct flow be set?
No The ufh tube is air locked, kinked or wrongly connected.
Yes
Try each zone singularly in turn and re-balance all the flow rates.
If all the design flow rates are still unachievable consult Nu-Heat
Technical.
Problem:
Low water temperatures on the Optiflo manifold
Solution:
After more than 48 hours of system operation by adjusting the water temperature control valve is
the design flow temperature achieved?
No Check the boiler is set to maximum.
Check the Energymaster cylinder (if fitted) thermostat is set to 6570C.
Check that the boiler auto bypass valve is set correctly to 0.4 bar.
If the design flow temperature is not achieved consult your installer as the boiler
is not providing sufficient heat to the underfloor heating system.
Yes
The blue button will

pop up when open
Direct water temperature

control valve
If there is more than 15C difference between the design flow temperature
and the return temperature allow more time for warm up and then increase
the flow rates.
Remote water temperature
control valve
21/9/07
15:33
Page 25
Problem:
No heat to one zone
Solution:
Is hot water flowing to the zone?

No Check the electrics, flow rates and flow temperatures as detailed above.
Zone:
Flow Rate l/ m :
Yes
The zone actuator heads are fitted to the wrong zones.

To check connections are correct:
Actuator heads must be

correctly labelled
Turn all room thermostats down to 5C,

Check one zone at a time (all other zones must be off),
Turn the thermostat in the zone up high,
If another zone is getting warm it indicates that the actuator controlled by the
thermostat is probably fitted to the wrong zone valve,
Continue to test all other zones and move actuators to their correct positions,
Re-label actuator heads when you are happy that they are correctly connected.
Problem:
Low heat to one/several zones
Solution:
Is the flow rate and temperature correct?

No Check the flow rates and flow temperatures as detailed above.
12:00
Yes Increase the flow rate to the maximum possible (see diagram below).
If the room(s) have a high heat loss, ie. a lot of external walls and windows, the timeclock
settings may be insufficient to allow for extended warm-up times. Set the timeclock to turn
on earlier.
Adjust timeclock settings

or programmable
thermostat
If the problem persists increase the flow temperature (see diagram below); do this gradually
as excessive temperatures may damage natural flooring and tiles.
If problems are still experienced after following the above instructions, please contact Nu-Heat Technical.
Manifold components
Flow gauges
(see A3 manifold & zone information)
Flow temperature gauge

Flow adjustment
Manual air vent
Filling/drain off valve
Floor heating pump
(direct mounted)
Main isolating valve

(return flow is behind)
Actuators
Pressure gauge
Filling/drain off valve

Temperature blending valve
Return temperature gauge
7.1 Problem solving
7.1 Problem solving underfloor heating, continued
21/9/07
15:33
Page 26
7.2 Problem solving
7.2 Problem solving EnergyMaster domestic hot water

Problem:
Low pressure
Solution:
Is there sufficient flow from the cold water taps?

No Mains pressure into the building is insufficient or restricted.
Yes
Check that the cylinder isolating valve is not restricting flow, and that the supply
pipework is correctly sized.
If there is a build-up of limescale in the cylinder heat exchanger either power-flush
or use a chemical descaler in accordance with regulations.
Problem:
Lack of hot water
Solution:
Is the cylinder hot? (feel the automatic air vent on top of the cylinder it may be very hot)
No Check that the cylinder thermostat is set between 65C and 70C.
Check whether turning up the thermostat opens the cylinder zone valve and
turns on the boiler and boiler pump.
Check that the boiler bypass valve (if fitted) is not too far open, bypassing the
cylinder.
Yes
Is the chrome pipework going into the top of the blending valve hot when the tap runs
cold? (this may be very hot).
No Check that the flow switch is operating the shunt pump.
Check that the shunt pump is pumping upwards and is set to
speed 2 or 3.
Check if the cylinder auto air vent is blocked as the cylinder
may be full of air clean and replace auto air vent.
Cylinder isolating valve
Automatic air vent
Cylinder thermostat
Yes
If the hot pipe going into the top of the blending valve is hot
and the output (from the horizontal pipe) is cold then the
temperature blending valve is incorrectly set or faulty.
OR
Systems with a secondary hot water loop
If the horizontal output pipe of the blending valve is hot, the
non-return valve may have failed.
Blending valve pipework
Shunt pump
21/9/07
15:33
Page 27
If there is any aspect of the installation that you do not understand, please contact
Nu-Heat Customer Support for advice.
All illustrations and diagrams in this manual are the property of Nu-Heat.
All rights reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means electronic,
mechanical, photocopying, recording or otherwise without prior written
permission of Nu-Heat.
21/9/07
Heathpark House, Devonshire Road

Honiton, Devon ex14 1sd
Tel: 01404 549770
Fax: 01404 549771
Web: www.nu-heat.co.uk
Email: ufh@nu-heat.co.uk
15:33
Page 28

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Combined plumbingV4 Sept07:Layout 1

warm water underfloor heating

Combined plumbingV4 Sept07:Layout 1

installation manual for nu-heat warm water underfloor heating

It is a condition of the warranty that the Certificate of Installation and

Combined plumbingV4 Sept07:Layout 1

Recommended installation sequence

Direct mounted pump module

Connecting to the Optiflo Manifold

Filling, flushing and pressure testing room zones

Installing the EnergyMaster cylinder:

Filling the EnergyMaster cylinder

Temperature/pressure relief valve discharge

Filling the boiler and heating system pipework

Filling the boiler

Filling the heating system pipework with a

Setting flow rates and Commissioning

Commissioning the EnergyMaster2 cylinder (where fitted)

Aquastar hot water loop

Problem solving Underfloor heating

Problem solving EnergyMaster2 cylinder

Combined plumbingV4 Sept07:Layout 1

1.2 Recommended installation sequence

Lay the floor insulation.

Install and pressure test the underfloor heating tube.

1.2 Installation sequence

Combined plumbingV4 Sept07:Layout 1

1.3 System components

Combined plumbingV4 Sept07:Layout 1

1.3 System components

Optiflo Manifold may be connected either left or right-handed

14mm Fastflo & 16mm Alupex floor tube

10mm Fastflo floor tube

1.3 System components Optional plumbing components

Optional heated towel rails

1.3 Optional components

Combined plumbingV4 Sept07:Layout 1

Combined plumbingV4 Sept07:Layout 1

1. Unscrew the manifold-rail mounting

3. Refit the boss on the front of the rail,

The Supply (flow) manifold must be the

Note: The manifold brackets are designed

600mm minimum to floor

1.4 Optiflo manifolds

1.4 Optiflo manifolds

Combined plumbingV4 Sept07:Layout 1

Direct Mounted Pump Module

The Direct Mounted Pump Module connects

Reversing the direction of the pump

1. Reverse the manifold on its brackets,

2. Remove the mixing valve castings from

3. The mixer casting will need the pump

4. Using a spanner unscrew the pump

5. Replace the blanking cap and pump

6. Remount the casting onto the pump,

1.5 Pump modules

1.5 Pump Modules

Combined plumbingV4 Sept07:Layout 1

1.5 Pump modules

1.5 Pump Modules continued

The Remote Mounted Pump Module is located remotely from the

Reversing the direction of the remote pump

Note: At some point between the Pump