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The DATA HIU
Installation Instructions D3
The DATA HIU, Installation Instructions D3 13/06/2017

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Summary of Contents for THERMAL INTEGRATION DATA

  • Page 1 The DATA HIU Installation Instructions D3 The DATA HIU, Installation Instructions D3 13/06/2017...
  • Page 2: Table Of Contents

    The DATA HIU, Installation Instructions D3, 13th June 2017 The DATA HIU, Installation Instructions D3 Wiki Binder, 13th June 2017 About Thermal Integration ..........3 Explanation of symbols and abbreviations ........4 Overview of Components and Connections ........5 Options ............. 6 Dimensions ............
  • Page 3: About Thermal Integration

    The DATA HIU, Installation Instructions D3, 13th June 2017 About Thermal Integration About Us We design and manufacture pre-fabricated Hot Water and Central Heating Cylinders, Thermal Stores, Buffer Tanks and Heat Interface Units to suit almost any domestic or commercial application. Our range of products is the end result of over 20 years of continuous development and improvement in heating technology.
  • Page 4: Explanation Of Symbols And Abbreviations

    The DATA HIU, Installation Instructions D3, 13th June 2017 Explanation of symbols and abbreviations Symbols Abbreviations Page 4...
  • Page 5: Overview Of Components And Connections

    The DATA HIU, Installation Instructions D3, 13th June 2017 Overview of Components and Connections 1 Primary circuit strainer 13 Domestic Hot Water primary return temperature sensor 2 Back casing 14 Central heating strainer 3 Primary flow temperature sensor 15 Filling point...
  • Page 6: Options

    The DATA HIU, Installation Instructions D3, 13th June 2017 Options The unit has several options available depending on requirements. The basic unit can be equipped with any combination of thefollowing: Option A1: Spool piece, used when neither option A2 or A3 are required.
  • Page 7: Dimensions

    The DATA HIU, Installation Instructions D3, 13th June 2017 Dimensions Page 7...
  • Page 8: Technical Data

    The DATA HIU, Installation Instructions D3, 13th June 2017 Technical Data Description Data Nominal primary supply temperature Maximum primary supply temperature Minimum primary supply temperature 55C * Nominal DHW supply temperature DHW Set Range 45C to 60C Return Temp Limit Range...
  • Page 9: Application

    The DATA HIU, Installation Instructions D3, 13th June 2017 Application The Data twin plate HIU is used to provide hot water and central heating in properties connected to a district heating systemusing a centralised boiler. Please keep the following conditions in mind during installation: The unit must be installed in a frost free area.
  • Page 10 Components, pipes and radiators in, and connected to the unit may be hot. The DATA heat interface unit is designed for use with centralised heating systems up to 85C.
  • Page 11: General Plumbing Requirements

    The DATA HIU, Installation Instructions D3, 13th June 2017 General Plumbing Requirements NEW COMPLETE SYSTEM INSTALLATIONS When carrying out a completely new heating system installation in a new build property or a first time installation in an existing property, then the heating system must conform to current building regulations Part L1a. All new domestic heating systems must have a minimum of two heating zones.
  • Page 12: General Wiring Requirements

    The DATA HIU, Installation Instructions D3, 13th June 2017 General Wiring Requirements These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. Component specific electrical information may also be supplied in support of these instructions, however if there is any doubt please contact...
  • Page 13: Schematic Layout

    The DATA HIU, Installation Instructions D3, 13th June 2017 Schematic Layout Page 13...
  • Page 14: Wiring Diagram

    The DATA HIU, Installation Instructions D3, 13th June 2017 Wiring Diagram Power Supply The heat interface unit is equipped with a wiring centre that converts the 230 VAC power supply to 24 VDC and powers the CH pump and optional DHW pump. It also houses the main fuse for the unit.
  • Page 15 The DATA HIU, Installation Instructions D3, 13th June 2017 Room thermostat The unit can be equipped with a on/off thermostat that has potential free contacts or a Honeywell round on/off (T87G2014) thermostat with power stealing technology. Full Wiring Diagram with Ethernet Billing...
  • Page 16: Installation Requirements

    Installation Requirements Components, pipes and radiators in, and connected to the unit may be hot. The DATA heat interface unit is designed for use with centralised heating systems up to 85C. The pipes and components in the unit and the pipes and radiators in the central heating installation can reach temperatures of 80C and contact may lead to burns.
  • Page 17 The DATA HIU, Installation Instructions D3, 13th June 2017 DHW Recirculation Unit The DHW recirculation unit is an available option within the unit. The circulation system connected to the unit must not contain anyclosable valves. Applying valves to the system can cause the pump to overheat due to insufficient flow.
  • Page 18: Installation Setup

    The DATA HIU, Installation Instructions D3, 13th June 2017 Installation Setup Parts Supplied and Required for Installation Connections Page 18...
  • Page 19: Stage 1 - Pre-Fix Bracket Positioning

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 1 - Pre-Fix Bracket Positioning The following dimensions for for the extended pre-fix kit.If a flushing by-pass is to be fitted, please refer to the relevant page. 1.Mark out the wall with the fixing points using the dimensions shown below.
  • Page 20: Stage 2 - Hiu Preparation

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 2 - HIU Preparation 1.Remove casing carefully. If the unit is supplied with a security bracket, this will first need to be removed. 2.Remove bag of accessories. 3.Remove protective caps from connections...
  • Page 21: Stage 3A - Fixing Hiu

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 3a - Fixing HIU Please use the enclosed screws and plugs to mount the unit. The fixing must be able to withstand at least the unit weight. Please allow for a minimum of 30Kg.
  • Page 22: Stage 3B - Pipework Connections

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 3b - Pipework Connections Page 22...
  • Page 23: Stage 4 - Fitting A Heat Meter

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 4 - Fitting a Heat Meter Units are typically supplied with heat meters factory fitted as per requirements, however a heat meter can be fitted by following these steps. 1. Remove Spool Piece 2.
  • Page 24: Stage 5 - Filling The Heating System

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 5 - Filling the Heating System The method of filling the CH system must comply with the current water supply (water fittings) regulations and use approved equipment. For GB Please refer to Guidance G24.2 and recommendation R24.2 of the water regulations guide. For IE Please refer to the current edition of I.S.
  • Page 25: Stage 6 - Bleeding The Unit

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 6 - Bleeding the Unit To ensure the unit functions properly, it must be bled first. This can be done from two places within the unit. The system must also be bled at the radiators.
  • Page 26: Stage 7 - Programmer And Room Thermostat Connection

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 7 - Programmer and Room Thermostat Connection The unit can (optionally) be connected to a programmer / room thermostat, to control central heating timing and / or temperature. Connecting the programmer / room thermostat: 1.Locate the brown and white twin cable (600mm Long) at the back of the HIU electronic controller, remove and discard the...
  • Page 27: Stage 8 - Connect Power

    The DATA HIU, Installation Instructions D3, 13th June 2017 Stage 8 - Connect Power 1. Close all isolation valves in the property. 2. Check all coupling nuts for leakage. (nuts may become looseduring transport) 3. Make sure the electronics are securely mounted to the frameand avoid cables and pulse pipes from fouling the casing.
  • Page 28 The DATA HIU, Installation Instructions D3, 13th June 2017 Page 28...
  • Page 29: Adjusting Settings

    The iHIU Controller is a miniature Linux web server that can be supplied separately to provide more advanced control and monitoring of the Data HIU. The controller is typically mounted within the casing of the HIU, with an option for a display on the front of the HIU.
  • Page 30: Securing The Casing

    The DATA HIU, Installation Instructions D3, 13th June 2017 Securing the Casing To secure the unit, a metal security casing is fitted. The casing will obstruct from removing the EPP casing without damaging the seal. It also functions as a mount for the display of the heat meter.
  • Page 31: Service &Amp; Inspection

    The DATA HIU, Installation Instructions D3, 13th June 2017 Service & Inspection To ensure the unit functions properly, it is advised to periodically inspect the installation. Maintenance and repairs should be carried out by recognised personnel only. Remove the power from the unit when performing maintenance and/or repairs.
  • Page 32: Draining The Unit

    The DATA HIU, Installation Instructions D3, 13th June 2017 Draining the Unit Should the unit need draining, please follow the below steps. 1.Disconnect the power to the unit 2.Open all radiator valves. When thermostatic valves are C fitted, switch them towards their maximum setting.
  • Page 33: Pump Settings (Wilo)

    The DATA HIU, Installation Instructions D3, 13th June 2017 Pump Settings (Wilo) The heat interface unit is fitted with one of two central heating pumps. The pumps can be adjusted to fit the end users situation. By default, the pumps are placed in the maximum setting with a constant differential pressure.
  • Page 34: Pump Settings (Grundfos)

    The DATA HIU, Installation Instructions D3, 13th June 2017 Pump Settings (Grundfos) The Grundfos pump has 3 control modes (proportional pressure, constant pressure and constant curve). Each control mode has 4 settings to choose from. The user interface has 1 push button, one red/green LED and 4 yellow LEDs.
  • Page 35 The DATA HIU, Installation Instructions D3, 13th June 2017 Performance View While the pump is running, the first LED will show a green light. The following 4 LEDs will indicate the power consumption as shown in the table below. Page 35...
  • Page 36: Dhw Recirculation Pump (Optional)

    The DATA HIU, Installation Instructions D3, 13th June 2017 DHW Recirculation Pump (Optional) The domestic hot water circulation pump is an available option within the unit. The pump is added to minimize delay in the delivery of domestic hot water at the draw off point in a closed DHW circulation circuit.
  • Page 37: Differential Pressure Valve (Optional)

    Differential Pressure Valve (Optional) The DATA HIU comes as standard with a function to learn the differential pressure of the primary system during operation, adjusting its performance characteristics to suit. This self learning feature works by examining the effect of a valve movement compared to known characteristics, and hence determining what the differential pressure actually is.
  • Page 38: Troubleshooting (End Users)

    The DATA HIU, Installation Instructions D3, 13th June 2017 Troubleshooting (End Users) What can you do? Always take in account the safety of yourself and others when performing a troubleshoot. Leakage 1. Close all valves on the plumbing bracket under the unit and the mains cold water feed.
  • Page 39: Troubleshooting For Technicians

    PDF Binders, Installation Instructions Troubleshooting for technicians Complaint LED Indication light Cause Solution Leakage - Close all valves on the fix rail and clos the main water supply valve. Coupling nut leaking. Coupling nut is loose. Tighten coupling nut. Gasket is missing. Fit gasket.
  • Page 40: Heat Meter

    The DATA HIU, Installation Instructions D3, 13th June 2017 Heat Meter The Zenner Zelsius® C5 ultrasonic heat and refrigeration meter operates with an innovative ultrasonic technology, specially developed for domestic energy measurement. Thanks to a combination of modern measuring technology and a...
  • Page 41: Dirt And Air Separation

    The DATA HIU, Installation Instructions D3, 13th June 2017 Dirt and Air Separation Dirt and Air Separation Air bubbles and dirt particles are always present in the water of cooling and heating systems. The dirt can accumulate and cause blockages. The use of filters is not ideal because these do not trap smaller particles, silt up and then have to be regularly cleaned or replaced.
  • Page 42: Guarantees And After Sales

    Consumables as specified by us, including but not limited to: hoses, gaskets and batteries 7. Report any faults to your installer, service engineer or Thermal Integration directly. Faulty parts must be accompanied by a fully completed Thermal Integration Warranty Return form, to be returned to Thermal Integration. Returned items remain the property of Thermal Integration Ltd.
  • Page 43 All pipework has been correctly tested and flushed d. Credit on billing system to enable security valve A minimum 2 weeks notice is required in writing to Thermal Integration before the requested commissioning date. SERVICE Technical assistance and engineer backup can be obtained by calling our offices:...
  • Page 44: Data Ec Declaration

    The DATA HIU, Installation Instructions D3, 13th June 2017 DATA EC Declaration Page 44...

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