Installation Instructions for the Data Extra HIU

Explanation of symbols and abbreviations

Symbols

Abbreviations

Introduction

The DATA Extra HIU enables us to take the functions of our flagship twin plate DATA HIU and increase the heating output to cater for commercial or industrial applications. The basis of this HIU is our SLIM hot water only HIU and then we add a heating plate heat exchanger and Danfoss pressure independent control valve with a Novocon Actuator for the heating side of the HIU. Both the heating and hot water controls are linked to our Node-iHIU system and can be accessed remotely for monitoring and adjustment.

The fully insulated HIU is enclosed within a white steel enclosure designed to keep the overall footprint of the HIU to an absolute minimum. If required, the expansion vessel, safety relief valve, filling loop and pump are mounted external to the casing, allowing the HIU to be fitted out of the way, with key components mounted in a more accessible location.

The heating installation must be equipped with a correctly sized expansion vessel and safety relief valve fitted between the HIU and any isolation valve on the heating circuit. It is also advisable to fit a filling loop and pressure gauge to the heating system, in a location convenient for the end user to access and top-up the central heating system. Refer to the chapter on "Installation Requirements" for more information. Contact Thermal Integration for more information on parts availability and advice on system safety.

Key Components

Parts List

Item No.	Description	Pt. No.
1	SLIM HIU	70TILSLIM
2	Node-iHIU Control	70DATA-Extra-Control
3	CH Plate Heat Exchanger	7028768
4	CH Control Valve	70610
5	CH Control Valve Actuator	70NOVO003Z8500
6	Heat Meter	70HM403-2.5-G1B-130
7	Primary Flow Temperature Sensor	70HSF51862
8	Primary Return Temperature Sensor	70HSF51862
9	CH Flow Temperature Sensor	70HSF51862
10	Manual Air Vent	N/A
11	Heat Meter Flow Temperature Sensor	N/A
12	DHW Plate Heat Exchanger	7066561
13	DHW Stepper Control Valve	70HSF51495
14	Universal HIU Controller	70HSFCONTROL
15	DHW Flow Sensor	70HSF50274
16	DHW Temperature Sensor	70HSF52727
17	Primary Return Temperature Sensor	70HSF52726
18	Primary Flow Temperature Sensor	70HSF52727
Not Shown	Optional Differential Pressure Sensor	70200216-2

Available Options

The unit has several options available depending on requirements. The basic unit can be equipped with any combination of the following:

• Landlord security valve, allows the landlord to remotely isolate the unit from the district heating network if required.
• Differential pressure control valve, to balance differential pressures between the primary flow and return. Only required where the differential pressure exceeds 250kPa. (Max 450kPa)
• Flushing Bypass for connecting to the primary flow and return pipework (External to the unit)
• External DHW recirculation unit, to provide constant circulation of DHW throughout the property in order to allow quicker response times at the tap where extended pipe runs are unavoidable.
• Heat Meter. It is possible to fit most brands of heat meter into the HIU, contact Thermal Integration for further information.

Dimensions

Technical Data

Primary
Nominal primary supply temperature	85°C
Maximum primary supply temperature	90°C *
Minimum primary supply temperature	55°C **
Maximum primary differential pressure	250kPa
Minimum primary differential pressure	50kPa ***
Pressure class DH circuit	PN16
Domestic Hot Water
Nominal DHW supply temperature	55°C
DHW Set Range	45°C to 60°C
Domestic Hot water heat exchanger (DHW)	E8LAS‐40
Keep Warm Modes	Economy / Comfort
Keep Warm Temperature	25°C to 60°C
Keep Warm Duration	0 to 120 mins or Always On
Max Return Temperature during Keep Warm Mode	DHW Setpoint -2°C
DHW Max pressure	6 Bar
Pressure class DHW circuit	PN10
DWH Priority	Multi-Stage ****
Central Heating
Maximum flow temperature	Primary T -5°C
Return Temp Limit Range	35°C to 55°C
CH Limit Range	30°C to 80°C
Central heating heat exchanger (CH)	B25TH‐30
Pressure class CH circuit (3 bar safety valve)	PN16
CH working pressure	N/A (By Installer)
Nominal pump pressure	20 kPa (Adj. 0-70)
Maximum recommend flow rate	750 l/hr
General
Primary connections	DN32 Female
Mains & DHW connections	¾” Female
Central heating connections	¾” Female
Casing width	653mm
Casing height	900mm
Casing depth	225mm
Casing Material	Steel
HIU Insulation Material	EPP Expanded Polypropylene
Pipework Insulation Material	Grey Polyethylene Foam
Maximum Heat Losses	<50W (1.2 kWh/day)
Weight (basic version)	35kg Approx
Electrical supply info	230V 50Hz - 0.64A
Power consumption per year	circa 45kWh
Fuse ratings	3 Amp
Sensors	NTC 10kohm @ 25°C

.* Maximum primary supply temperature 100°C for momentary spikes.
.** Minimum required DH supply temperature is DHW setpoint + 5°C with a minimum of 55°C.
.*** Depends on requested DHW output and available DH supply temperature.
.**** See Multi-Stage DHW Priority example below.

Description

The HIU is for use in properties connected to a district heating system using a centralised boiler and is suitable for both central heating and domestic hot water. Each hydraulic circuit to which the HIU is connected, must meet minimum water quality standards as stated in document "Requirements on water quality" available on our Wiki Site at www.heatweb.co.uk/w.

Please keep the following conditions in mind during installation:

• The unit must be installed in a frost free area.
• The unit must not be exposed to direct sunlight.
• Ambient temperature should be between +5°C and +40°C.
• Humidity should be between 10% and 85%.
• The unit must be connected to a fused double pole isolator.
• The unit uses 230 VAC. Use caution when handling. Contact may lead to shock, burns or electrocution.
• Components in the unit and connected to the unit can reach high temperatures. Contact may lead to burns.

DHW Status Indicator LED

• Green blinking slowly (about 1x per second): HIU is at rest; there is no heat demand and all control valves are closed.
• Blue blinking: HIU is in Hot water mode; there is a water draw-off and the control valve is open.
• Red blinking: Error
• White continuous (only for engineers): HIU is in service mode
• No LED: HIU is switched off

Operation

The HIU is equipped with two heat exchangers, the left hand heat exchanger transfers the heat from the district heating system to the DHW circuit and the right hand heat exchanger transfers the heat from the district heating system to the CH circuit. These heat exchangers ensure hydraulic separation between the property and the district heating network. The hot water in the district heating network does not come into contact with the hot water or heating circuit of the property. Heat is transferred from the district heating network via the heat exchangers to the domestic hot water system and central heating system.

Central heating

The temperature of the property's heating system is controlled automatically by the HIU, with the temperature set-point being adjustable via the Modbus interface. When heating demand finishes, the heating pump will be switched off after a defined pump over-run time (default: 15 minutes).

Domestic Hot Water

The electronics within the unit, together with domestic hot water control valve, temperature sensors and flow sensor, regulate the temperature of the hot water to it's set point (As Standard 55°C). The HIU has a very low switching point, recognising DHW flow rates as low as 1 l/min.

Each HIU has two domestic hot water keep hot modes, 'Eco' or 'Comfort' mode. These can only be selected during commissioning or by a trained engineer.

'Eco' mode can be specified to run for 0 minutes (which turns the feature off all together), 15, 30, 60 or 120 minutes after the last hot water draw off. In 'Eco' mode the heat exchanger is kept to a specified temperature (between 25 and 60°C) for the selected period of time and after this period of inactivity has elapsed the control valve closes completely and the temperature in the domestic hot water circuit is allowed to drop through natural dissipation to minimize energy consumption. If a hot water draw off is made any time throughout the Eco mode function the unit will deliver hot water as usual and the 'Eco' mode function will begin counting down for the selected time once again. In 'Comfort' mode the heat exchanger is continuously supplied with a trickle of primary water for quicker hot water delivery, however energy consumption will be slightly higher than if the unit was set in 'Eco' mode.

To prevent legionella from growing the heat exchanger is heated to 60°C for at least 60 minutes every 24 hours. (it is not possible to specify the time at which this occurs)

The hot water temperature is regulated to temperatures as high as 60°C. If there is a power outage during DHW draw off, units not fitted with a landlord security valve will stop regulating the hot water temperature. This may lead to a hot water temperature that is higher or lower than the setpoint. Hot water can cause burns.

Adjusting Settings

The DATA Extra requires connection to either a PC running the commissioning software, or by the use of an iHIU Controller, in order to adjust settings.

End users cannot adjust settings, unless an iHIU Controller is used.

PC Software

The software is made freely available, along with training, to registered commissioning engineers. Please contact Thermal Integration for further information.

The software allows one to adjust the following settings:

Setting	Options	Default
Domestic Hot Water Temperature	45°C to 60°C	50°C
Primary Differential Pressure	Auto or Manual from 0.3 to 2.0 bar	Auto
Warmup Boost Flow Rate	8 to 20 l/min	20 l/min
Return Temperature Limit	Disabled or Enabled from 35°C to 65°C	Enabled 50°C
Maximum Central Heating Temperature	30°C to 80°C	80°C
Central Heating Pump Timeout	0 to 30 minutes	15 minutes

iHIU Controller

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.

The controller provides a WiFi zone, and can log onto existing networks through either WiFi or Ethernet to gain access to the internet. The HIU can then be controlled directly from other devices on the local network, such as smartphones. Once connected to the internet the system can provide remote control and monitoring services, as well as many other features, some of which are listed below:

• Browser based cross platform interface that adjusts to screen size
• Allows setting of all the parameters available to the PC software, except via a browser
• Control over central heating as well as other settings via Google Calendar
• Remote commissioning
• Remote fault alarms and message forwarding via email or SMS
• Voice control over services via Android app
• Connection to Energy Saving Trust's Embed Database for free and secure online storage of all system data

Factory Settings

DHW Settings

The DHW settings are factory set, and these can only be changed by connecting a laptop directly to the SLIM HIU communication cable and using the HIU Monitor Application Software available from Thermal Integration. If the DATA Extra HIU is connected to a BMS, it is possible to alter the settings through the BMS ModBus interface.

The factory settings are as follows:-

Setting	Limits	Set Value
Temperature - DHW	45 - 60°C	55°C
Pressure	Manual / Auto	Auto
Ecoheat Time (keep warm)	Off,15, 30, 60, 120, Always	Off
Ecoheat Temperature	25 - 60°C	N/A
Legionella Prevention Cycle	On / Off	Off
District Heating Warmup Boost	8 - 20 l/min	20 l/min

Central Heating Settings

Setting	Limits	Set Value
Temperature - CH	20 - 80°C	60°C
Pump Over-run	any	60 secs
Return Temperature Monitoring	On / Off	Off
Return Temperature Limit	30 - 55°C	55°C*
CH Control Valve Pre-set	10 - 100%	100%

• If the Return Temperature Monitoring function is set to 'Off' the Return Temperature Limit is irrelevant.

Multi-Stage DHW Priority

If DHW priority is not suitable for the installation location (for instance in a restaurant or hair dressers, where hot water draw-offs may be frequent and therefore hold off the heating output), the primary flow rate available for the HIU to operate simultaneously in both DHW and CH modes, does not need to be the sum of the two circuits. This is due to the Multi-Stage DHW Priority feature built into the HIU software.

This feature allows peek or multi-staged flow limits to be set, which enables the DHW priority to be off-set against a proportion of the heating flow. Although it is possible to set specific flow rates and reductions, An example of the basic principle is explained below:-

DHW primary flow rate =
0 to 25%, no effect on the heating output
25 to 50%, heating output reduced by 25%
50 to 75%, heating output reduced by 50%
75 – 100%, heating off completely.

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. Each of these zones should be controlled by a thermostat and zone valve. Alternatively individual electronically controlled Thermostatic Radiator Valves may be fitted. If domestic hot water is provided by a storage system then the storage system or cylinder will require separate time and temperature control.

All radiators must have TRV's fitted in all rooms except bathrooms and any rooms where a thermostat is located. The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.

EXISTING INSTALLATIONS: When carrying out boiler replacements on an existing system, the regulations do not require separate zoning of the upstairs and downstairs and compliance with the regulations can be achieved by a single room thermostat or programmable room thermostat. It is however recommended that TRV's are fitted to all rooms except the bathrooms and the room where a thermostat is located.

The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements.

BRITISH & IRISH STANDARDS Where no specific instruction is given, reference should be made to the relevant British and/or Irish Standard codes of Practice.

• BS7074:1 Code of practice for domestic and hot water supply
• EN12828 Central heating for domestic premises
• BS7593 Treatment of water in domestic hot water central heating systems
• ECTI National rules for electrical installations

POTABLE WATER: All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

FITTING AND MODIFICATIONS: Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer. Any misuse or unauthorised modifications to the appliance or associated components and systems could invalidate the guarantee and may lead to serious injury or even death. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

SERVICING: The end user should be advised to have the system serviced annually by a competent engineer. Contact Thermal Integration Ltd for a list of approved engineers. Approved spares must be used to help maintain the economy, safety and reliability of the appliance. The service engineer must complete the Service Record after each service.

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 Thermal Integration Ltd. (Tel: 0345 2411441)

FAILURE TO INSTALL APPLIANCES CORRECTLY COULD LEAD TO PROSECUTION.

The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements.

BRITISH & IRISH STANDARDS: Where no specific instruction is given, reference should be made to the relevant British and/or Irish Standard codes of Practice.

• BS7074:1 Code of practice for domestic and hot water supply
• EN12828 Central heating for domestic premises
• BS7593 Treatment of water in domestic hot water central heating systems
• ECTI National rules for electrical installations

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

Danger of short circuit: When connecting the cables ensure that no cable pieces fall inside the control panel.

The Mains supply to the appliance must be through a fused double pole isolator situated next to the appliance. The isolator must have a contact separation of 3mm minimum in all poles and should isolate the appliance and all associated controls.

Unless otherwise stated, all Heat Interface Units should be connected to a mains 230V 50Hz Supply fused at 3 Amps.

All electrical connections with the Heat Interface Unit control panel are clearly marked as follows:

• L = Live 230V
• N = Neutral
• E = Earth

Any additional mains cable should comply fully with the current I.E.E. wiring regulations. It must have a minimum section of 0.75mm² and be capable of withstanding a minimum of 85°C.

Schematic

Installation Schematic

NOTE: The below schematic shows the HIU fitted with a CH pump, however this is an optional extra.

Wiring Diagrams

Wiring Schematic

Power Supply

The heat interface unit is equipped with a wiring centre with a 230 Vac power supply and relay to power a CH pump. It is also fitted with a 24Vdc transformer to power the DHW HIU and CH Control valve Novocon actuator, and there is a 5Vdc transformer to power the Raspberry Pi iHIU Control.

Room thermostat connection

A room thermostat can be connected to the HIU, the HIU will then respond to a heating demand from the room thermostat. The connection of a room thermostat is not mandatory, the HIU is supplied with a link across the thermostat connections which creates a closed contact to simulate a heat demand on the HIU.

The room thermostat must be an on/off thermostat with potential free contacts. Thermostats that do not have a potential-free contact must not be fitted.

Important Installation Requirements

Components in the HIU, pipes and radiators may reach high temperatures. The HIU is designed for heat distribution networks with water temperatures up to 95°C. The pipes and parts in the HIU as well as pipes and radiators in the heating system can also reach this temperature. Contact can lead to burns.

Central Heating

When installing the HIU, the following conditions must be observed (see the following diagrams):

1. The heating installation must be equipped with a correctly sized expansion vessel and safety relief valve fitted between the HIU and any isolation valve on the heating circuit.

2. It is advisable to fit a filling loop and pressure gauge to the heating system, in a location convenient for the end user to access and top up the central heating system.

3. The heating system must be equipped with a WRAS approved over pressure safety relief valve (rated to 3 bar), fitted between the HIU and any isolation valve on the heating circuit.

4. A heating control valve must not be installed in the heating circuit. The room thermostat should, if used, be connected to the room thermostat cable of the HIU.

5. Before the unit is commissioned, the central heating circuit must be fitted with an automatic bypass valve to maintain a minimal flow rate and regulate pressure across the system. The valve must be installed between the central heating flow and return, noting the direction of flow. The automatic bypass must be fitted before any isolation valve on the heating circuit.

NOTE For optimal energy efficiency and comfort, it is of the utmost importance to hydraulically balance the CH system correctly. For the same purpose it is advisable to design the CH system in such a way that the CH return temperatures are as low as possible.

* Artificially softened water must not be used to fill the central heating system

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DHW Recirculation Unit

The DHW recirculation unit is an available option for fitting external to the HIU. The recirculation system must not contain any isolation valves. Applying valves to the system can cause the pump to overheat due to insufficient flow.

Keep the following conditions in mind during installation:

• Maximum pressure supplied by the domestic water circuit is 10 bar.
• All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be WRAS approved.

Service and Inspection

Components in the HIU, pipes and radiators may reach high temperatures. The HIU is designed for heat distribution networks with water temperatures up to 95°C. The pipes and parts in the HIU as well as pipes and radiators in the heating system can also reach this temperature. Contact can lead to burns.

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.
• Connect the flow and return valve from the district heating network.
• Connect the flow and return valve on the unit.
• Check the unit for leaks.
• Check the primary and central heating strainer for debris and clean if necessary.
• Check valves for debris and clean if necessary.
• Check the unit operates satisfactorily in domestic hot water and central heating modes.
• The casing can be cleaned with a damp cloth. Do not use detergents of any kind.

The unit uses electrical components (230Vac, 24Vdc & 5Vdc). These components must stay dry at all times. Contact with these energised components can result in an electrical shock, burn, or electrocution.

Prolonged Absence or Holiday

Do not switch the unit off during periods of prolonged absence or holiday. To prevent frost damage within the unit or the distribution network, the radiator and shutoff valves MUST remain open. Radiators can be switched to the frost protection position (slightly opened) and/or the room thermostat lowered to a MINIMUM of 10°C. It is recommended to flush all water tapping points and showers for at least 2 minutes after a long period of absence.

DHW Performance

DHW Performance Table

DHW Power Chart for 10-55°C

Primary Return Temperatures for 10-55°C

Primary Flow Rates for 10-55°C

Primary Pressure Drop for 10-55°C

Domestic Hot Water Pressure Drop for 10-55°C

Central Heating Temperature Curves

Primary Return Temperature

Primary Flow Rate - CH

Secondary Flow Rate - CH

Pressure Drops

Installation Set-up

Stage 1 - Removing the front cover

The front cover can be removed by extracting the 4 screws, one in each corner of the front cover. It is support by the top flange, so can simply be lifted off using the handles provided.

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Stage 2 - Mounting the HIU

The casing is mounted directly to the wall using the 4 keyhole slots punched into the back panel. It is important to use the correct fixings for the wall construction and to ensure that the wall is capable of supporting the weight of the HIU.

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Stage 3 - Pipe Connections

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Stage 4 - Installing the Heat Meter

The HIU is supplied with or without the heat meter (as per specification), however in order to change the heat meter, it is necessary to follow the procedure below:-

• The heat meter body and temperature sensors are all wet pocket connections, therefore it is important to take the necessary precautions against water spillage, when disconnecting any part of the heat meter.
• The heat meter body and display cannot be disconnect from each other, neither should any cables or sensors be cut, as this will invalidate the heat meter calibration and warranty.

1. Isolate the HIU, hydraulically and electrically.
2. Locate the heat meter measuring body and both temperature sensors. The hot sensors (red tag) should be mounted in the primary flow pipe and the cold sensor (blue tag) should be mounted into the heat meter body itself.
3. Loosen and extract the heat meter sensor from the primary flow pipe.
4. If there is an MBus cable connecting to the heat meter, this will need to be disconnected from the incoming MBus cable.
5. Loosen the union nut either side of the heat meter body, and extract the heat meter body together with the sensors and heat meter display.
6. Fit the new heat meter in the reverse order, using new sealing washers on both union connections.
7. Always check that the heat meter is fitted in the correct flow direction and that the sensors are fitted to the correct pipes. This can be done using the heat meter reading.

Stage 5 - Programmer and Room Thermostat Connection

The unit can (optionally) be connected to a programmer / room thermostat, to control central heating timing and / or temperature.

Connect a VOLT FREE programmer / room thermostat (sold separately) across the orange Switched Live 'SL' terminals in the main control box.

The room thermostat must be an on/off thermostat with potential free contacts. Thermostats that do not have a potential-free contact must not be fitted. .

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Stage 6 - Venting the Heating System

It is important that the central heating system within the property is completely bled of air. The HIU is equipped with a manual air vent, connected to the central heating circuit of the HIU.

Quick venting:

1. Vent the central heating system at the radiators. Start at the lowest point of the central heating system and finish at the highest. For fast bleeding of the HIU, turn the manual air vent cap counter clockwise, but do not remove this cap.

2. If necessary, the venting function of the pump can also be used to aid bleeding (see chapter "Setting the pump").

3. Continue venting the entire central heating system and the HIU until the entire system has been completely bled.

4. Make sure that all the vents on the radiators are closed tight and turn the cap of the manual air vent on the HIU, clockwise until finger tight.

Do not remove the manual air vent cap while the HIU is in operation. Ensure dirt is prevented from entering the air vent nipple, as it may cause a blockage. Ensure that it does not come into contact with chlorine products (≥ 250 ppm) and that steps are taken to eliminate water hammer in the central heating system.

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Stage 7 - Commissioning

Follow the steps below for connecting and commissioning the HIU. (assuming all hydraulic systems are filled and vented)

1. Close all isolation valves in the property.

2. Check all coupling nuts for leakage. (nuts may become loose during transport)

3. Make sure the electronics are securely mounted into the rear casing and ensure cables will not foul the front casing when fitted.

4. Connect the units power cable to the power outlet.

• Blue cable: N (Neutral)
• Brown cable: L (Live)
• Green/yellow cable: E (Earth)

5. Switch on the power supply to the unit. The DHW module should show a green blinking light.

6. Slowly open the district heating flow valve and check for leakage.

7. Slowly open the district heating return valve and check for leakage.

8. Fully open all (thermostatic) radiator valves in the property.

9. Bleed the central heating system. Start at the lowest and finish at the highest radiator or venting point (see chapter "Venting the Heating System"). Fill the heating system to a pressure of 2 bar. The pressure in the heating system should not fall below 1 bar.

10. Check that the central heating controls are calling for heat. The CH control valve will show 1,2,3,4 or 5 lights and the system begins to warm.

11. Slowly open a hot tap in the property. Check to see if the units DHW module shows a blue blinking light. Open the hot tap completely when the system is fully bled and leave it running for approximately 5 minutes. After 3 to 5 minutes check the water temperature at the tap is between 45°C and 60°C (Depending on the setpoint).

12. Bleed the unit. (see chapter "Venting the Heating System").

13. Close the hot tap in the property. The DHW module will now show a green blinking light.

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Stage 8 - Re-fitting the front cover

The front cover is fitted by locating the top flange first and then rotating the bottom of the cover down to line up with the screw holes.

Adjusting Temperatures and Settings

Domestic Hot Water

Instead of working in isolation, the SLIM HIU which provides the domestic hot water function of the DATA Extra HIU, is connected to the Node-iHIU controller and can be accessed through the BMS. It is possible to adjust the hot water temperature, select the keep warm function, view performance graphs and access HIU alarms.

We have a separate Wiki page for the SLIM HIU here. This includes a User and Installation Manual, which gives information specifically relating to the SLIM HIU.

Central Heating

AB-QM No Actuator

The Danfoss AB-QM Pressure Independent Control Valve has been used by Thermal Integration for many years now as a reliable means to control flow rates.

Depending on the design flow rate of the central heating circuit, the AB-QM control valve can be adjusted to limit the flow rate into the primary side of the plate heat exchanger. Adjustments can be carried out while the system is in use, and without the need for any tools. Reducing the Primary flow rate will reduce the temperature of the water flowing into the central heating circuit.

The DATA Extra HIU is fitted with the DN25 valve and details on its adjustment are shown on page 2 of the Installation Guide below, with related flow rates shown on page 4.

Novocon Actuator

The actuator used in the DATA Extra HIU is the Danfoss NovoCon and it is connected to the NODE-iHIU Controller via a digital cable. The actuator is set-up in our factory using the Danfoss NovoCon Configuration tool to work with the DN25 AB-QM Valve and with a 6 sec/mm Actuator speed, specifically for heating systems. The dip switches are set as per the photograph below and they must NOT be changed.

The NODE-iHIU controller accurately positions the NovoCon actuator to control the flow into the plate heat exchanger, and by doing so, it is able to accurately control the central heating output temperature and limit the Primary return temperature, if the central heating system is unbalanced.

The Primary return temperature function is disabled by default, however when enabled, the default limit is set to 55°C. It is possible to alter this temperature by accessing the HIU via a ModBus connection.

Status indicator LED's

SLIM HIU - DHW Status

The SLIM HIU Status LED is visible through a small hole in the case of the unit, and has 5 possible modes as follows:-

• Green blinking (slow): Standby condition
• Blue blinking: Domestic Hot Water Mode / Tap draw-off
• Red blinking: Error
• White continuous: Service mode (installer only)
• No LED: HIU is switched off

Danfoss NovoCon - CH Status

The NovoCon Actuator has a series of 5 LED's on the side of the body, and various combinations show the position / status of the actuator. Common combinations are shown below, refer to page 4 of the NovoCon Datasheet for an explanation of all other combinations.

Troubleshooting for 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.

2. Contact your engineer.

Central Heating Circuit does not warm up

1. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.

2. Make sure the valves on the plumbing bracket are open (handle in vertical position).

3. Check radiator valves are open and calling for heat.

4. Check the programmer is set to ON, and calling for heat.

5. Set the room thermostat higher.

6. Problem solved? If not, contact your engineer.

No domestic hot water

1. Check that the mains cold water valve is open. If not, open the main valve.

2. Problem solved? If not, contact your engineer.

Tap water does not warm up

1. Ensure that all valves on the plumbing bracket under the unit and the main valve are open.

2. Make sure the power cord is plugged in and turned on. If in doubt contact an electrician.

3. Problem solved? If not, contact your engineer.

Sound

NOTE: It is normal that the HIU makes noise when hot water or heating are active. Also, the electronic valves will make a light (buzzing) noise during movement. If the HIU starts to make any loud or disturbing noises, contact your installer.

Troubleshooting (for Technicians)

Guarantees and After Sales Backup for HIUs

Heat Interface Units (HIUs) carry the following guarantees as standard:

FACTORY WARRANTY

1. The warranty begins on the date of delivery. A dated delivery note will be issued to the customer and a copy will be stored by Heatweb Solutions.

2. 12 Months Parts and labour - Parts or labour proven to be defective will be replaced / repaired free of charge for a period of 12 months from date of delivery, provided the HIU is installed by a qualified engineer within 6 months of date of delivery.

24 Months Parts Only - Parts proven to be defective will be supplied free of charge (for fitting by others) for a period of 24 months from date of delivery.

3. Replacement of parts under warranty does not extend the duration of the warranty.

4. Any other costs are not covered by this warranty. All other damages of any nature whatsoever and howsoever arising, are expressly excluded from this guarantee.

5. The warranty conditions above only apply:

a. In the UK only on items provided exclusively by Heatweb Solutions.

b. If the product is installed by a Heatweb Solutions approved engineer in compliance with the installation instructions.

c. The installer must complete the commissioning checklist in full at the time the HIU is installed. This checklist must be returned to Heatweb Solutions within 30 days of commissioning. Checklists are enclosed in the HIU installation instructions.

d. If the installation complies with all current and relevant building regulations and codes of practice. (including the requirement to clean the primary and secondary heating systems and add corrosion inhibitor in line with BS7593:2006)

e. If the product is used and maintained exclusively according to the manufacturer's instructions and proof of periodic inspection / maintenance by a Heatweb Solutions approved engineer is available.

f. If the returned item is accompanied by a fully completed Heatweb Solutions Warranty Return Form.

6. Excluded are defects caused by:

a. Failure to maintain in accordance with manufacturer’s instructions.

b. Improper use.

c. Any attempt at repairs / maintenance by un-qualified persons.

d. where parts other than Heatweb Solutions Genuine Parts have been used in any service or repair.

e. Lightning, fire or natural disasters.

f. Deterioration and / or pollution from the district heating system or water network, either domestic hot water or heating side.

g. PH values of the primary medium being less than 7.5 or greater than 9.0.

h. Harmful additives to the heating water.

i. Consumables as specified by us, including but not limited to: hoses, gaskets and batteries.

7. Report any faults to your installer, service engineer or Heatweb Solutions directly. Faulty parts must be accompanied by a fully completed Heatweb Solutions Warranty Return form, to be returned to Heatweb Solutions. Returned items remain the property of Heatweb Solutions Ltd.

The Heatweb Solutions Warranty Return Form can be requested by phone or email. Returns are not accepted unless expressly agreed in writing.
Transport risk of returned items lies with the sender. The shipping of replacement parts are the responsibility of the supplier.

8. If the HIU breaks down, we may ask you to pay us a deposit before we visit you to repair it. We will return the deposit in full if we find a fault that is covered by this warranty. We may keep the deposit if we cannot access your property at the time we had arranged with you to visit or we find other conditions of this warranty have not been met. A responsible adult must be at the property to give our engineer this access to the HIU.

9. COMMISSIONING
Heatweb Solutions offer commissioning services across the UK. The service includes:

a. The fulfilment of the defined commissioning instructions.

b. Completion and return of site wide commissioning paperwork.

c. Rectification of any HIU problems.

d. Confirmation of HIU performance to contract specifications.

e. Engineer travel and subsistence.

Commissioning rates are charged on a whole day basis, and it is the responsibility of the client to ensure:

a. Safe access to properties and HIUs

b. Correct operation of central plant with delivery of heat to HIUs at specified temperatures, flow and pressures.

c. 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 Heatweb Solutions before the requested commissioning date.

SERVICE
Technical assistance and engineer backup can be obtained by calling our offices:

• Commercial Sales and Operations: 0345 2411441 | @ enquiries@heatweb.com
• Training: 0345 2411441 | @ enquiries@heatweb.com
• Service: 0345 2411441 | @ service@heatweb.co.uk

FURTHER INFORMATION

The Heatweb Wiki website at www.heatweb.com/wiki contains information on all aspects of HIU design, function, and servicing, and is always the best place to visit for additional documentation or how to guides.