Rehau Ba Technical document

rehaU intelligent Ba heating/cooling controlS
technical & inStallation manUal
Building Solutions
Automotive
Industry
www.rehau.co.uk

1
REHAU INTELLIGENT FLOOR
HEATING/COOLING CONTROLS
INDEX
1.0 . . . . . . Principles of Underfloor Heating/Cooling. . . . . . . . . . . . . . . . . . . 5
1.1 . . . . . . Principle of UFH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 . . . . . . Principle of UFC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 . . . . . . Fixed Flow Water Temperature (FFT) System. . . . . . . . . . . . . . . . . . . 7
1.4 . . . . . . Zone Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 . . . . . . Set Back Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.0 . . . . . . Fixed Flow Temperature Control . . . . . . . . . . . . . . . . . . . . . . 9
2.1 . . . . . . Required Components for Fixed Flow Temperature Control . . . . . . . . . . . . . 9
2.2 . . . . . . Fixed Temperature Mixing Options . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 . . . . . Compact Mixer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 . . . . . Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.3 . . . . . Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.3a . . . . . Before the System is Switched On . . . . . . . . . . . . . . . . . . . . . . 12
2.2.4 . . . . . Thermostatic Mixing Valve (TMV) . . . . . . . . . . . . . . . . . . . . . . 12
2.2.5 . . . . . Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.6 . . . . . Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.7 . . . . . Required Components for Zone Control . . . . . . . . . . . . . . . . . . . . 15
2.2.8 . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 . . . . . . Temperature Safety Options . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.1 . . . . . High Limit Sensor (HLS) . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.2 . . . . . Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.3 . . . . . Dew Point Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.4 . . . . . Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 . . . . . . 2-Port Zone Valve (ZV) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.1 . . . . . Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.2 . . . . . Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.0 . . . . . . REHAU Intelligent Heating/Cooling Control Systems . . . . . . . . . . . . . . 22
3.1 . . . . . . Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.1 . . . . . Components Overview Heating. . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.2 . . . . . Components Overview Heating/Cooling . . . . . . . . . . . . . . . . . . . . 24
3.1.3 . . . . . Components Overview Wireless Sensors/Controllers . . . . . . . . . . . . . . . 24
3.2 . . . . . . Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 . . . . . . Required Components for Zone Control . . . . . . . . . . . . . . . . . . . . 27

2
REHAU INTELLIGENT FLOOR
HEATING/COOLING CONTROLS
INDEX
4.0 . . . . . . Control System First Fix. . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 . . . . . . Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 . . . . . . Positioning the BA Master Controller Room Sensors and Remote Air/Floor Sensors. . . . 29
4.2.1 . . . . . Location of Room, Humidity Sensor and Air Sensor . . . . . . . . . . . . . . . . 29
4.2.2 . . . . . Positioning the Remote Air Sensor . . . . . . . . . . . . . . . . . . . . . . 29
4.2.3 . . . . . Positioning the Floor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.0 . . . . . . Control System Second Fix . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 . . . . . . REHAU BA Central Control Units . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 . . . . . . Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.1 . . . . . Boiler Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.2 . . . . . Pump Outputs - UFH Pump . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.3 . . . . . Connecting REHAU Add On, Extension Modules . . . . . . . . . . . . . . . . . 33
5.2.4 . . . . . Connecting Room Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.2.5 . . . . . Connecting Thermal Actuators (TH 1 – TH 8) . . . . . . . . . . . . . . . . . . 35
5.2.6 . . . . . External Switch/Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 . . . . . . Room Sensors Internal Connections.. . . . . . . . . . . . . . . . . . . . . . 36
5.3.1 . . . . . Connect the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.1a . . . . . Connect the Remote Air Sensor . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.2 . . . . . Floor Sensor Option (TD Sensor Only) . . . . . . . . . . . . . . . . . . . . . 37
5.3.3 . . . . . Connecting the Floor Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 37
6.0 . . . . . . Wireless Sensors/Controllers Set Up . . . . . . . . . . . . . . . . . . . . 38
6.1 . . . . . . Radio Frequency (RF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.1. . . . . . Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2. . . . . . Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.0 . . . . . . Setting Up BA Master Controller (Cooling) . . . . . . . . . . . . . . . . . . 40
7.1 . . . . . . Offset to Day Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 . . . . . . Night Setback Temperature (NSB). . . . . . . . . . . . . . . . . . . . . . . 40
7.3 . . . . . . BMS Used for Heating/Cooling Change Over Decision . . . . . . . . . . . . . . . 40
7.4 . . . . . . Exceeded Dew Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.5 . . . . . . Using Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.6 . . . . . . Dew Point Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.7 . . . . . . Volt Free Output Signal for Chiller/Reversible Heatpump . . . . . . . . . . . . . . 41
8.0 . . . . . . System Start Up and Operating Instructions . . . . . . . . . . . . . . . . . 42
8.1 . . . . . . Setting the Sensor Channel Number. . . . . . . . . . . . . . . . . . . . . . 42
8.2 . . . . . . REHAU BA Master Controller. . . . . . . . . . . . . . . . . . . . . . . . . 43

3
9.0 . . . . . . Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.1 . . . . . . Pre-commissioning Requirements . . . . . . . . . . . . . . . . . . . . . . 44
9.2 . . . . . . The Commissioning Team. . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.0. . . . . . CT Set Up Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.1. . . . . . Programmable Room Sensor, Domestic Hot Water, Radiator and Two Stage Controller . . 45
11.0. . . . . . Domestic Hot Water (DHW), Radiators and Two Stage Controller . . . . . . . . . 54
11.1 . . . . . . Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.2 . . . . . . Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.3. . . . . . Two Stage Room Temperature Controller . . . . . . . . . . . . . . . . . . . . 56
12.0. . . . . . Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
12.1. . . . . . Network Multiple Controllers . . . . . . . . . . . . . . . . . . . . . . . . . 57
12.2 . . . . . . Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
12.3 . . . . . . Holiday Override Function. . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.4. . . . . . Checking Control System Operation . . . . . . . . . . . . . . . . . . . . . . 60
13.0. . . . . . Troubleshooting and Error/Fault Messages. . . . . . . . . . . . . . . . . . 61
13.1 . . . . . . Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13.2 . . . . . . Error/Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13.3 . . . . . . Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
14.0. . . . . . Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
14.1. . . . . . Replacing Faulty Sensor/Controller. . . . . . . . . . . . . . . . . . . . . . . 65
15.0. . . . . . Sensor Failure/Actuator and Pump Exercise . . . . . . . . . . . . . . . . . 66
15.1 . . . . . . Sensors/Controller Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 66
15.2 . . . . . . Actuator and Pump Exercise . . . . . . . . . . . . . . . . . . . . . . . . . 66
16.0. . . . . . Wiring Schematic - Next Generation . . . . . . . . . . . . . . . . . . . . 67

4
REHAU Intelligent Controls
Technical Data
Power Supply 230V AC +10/-15%, 50 HZ
Max load pumps and Thermal actuators 4A + 35VA
Boiler relay Volt free signal. Max 4A
Main pump (Volt free relay) Volt free signal. Max 4A
Secondary pump 230V AC, 50Hz Max. 4A
Thermal actuators Max. 10VA on each output Max. 35VA in total
Max. 10VA per output. Max. 35VA in total
Optional External Switch (Timer) for night setback Open terminals for night set back and closed terminals for
day operation
Room sensor Bus 2 wire low voltage 5v
Application sensor and Limit sensor NTC type ETF-1899A for water temperature
Control signal for mixing valve actuator 0-10V DC
Power supply for mixing valve actuator 24V AC. Max 6VA
REHAU INTELLIGENT FLOOR
HEATING/COOLING CONTROLS
INDEX
If a floor heating system is added to an existing heating or hot water system, containing mild steel pipes,
a strainer must be fitted straight after the branch off.
All REHAU control systems must be installed.
- By a competent person
- In accordance with the latest issue of instructions supplied
with each component
- According to the current IEE wiring regulations laid out in BS 7671 and National Valid regulations and in
compliance with the ordinances stipulated by local power authorities.
Diagram/DWG Legend
AC Actuator
AV Air Vent
BPV Bypass Valve
BV Balancing Valve
CP Circulating Pump
CS Cylinder Sensor
CT2 Programmable Room Sensor
OS Outside Sensor
CYL Cylinder
DHWS Domestic Hot Water System
EV Expansion Vessel
FM Flow Meter
HLS High Temperature Limit Stat
IV Isolating Valve
LSV Radiator Lock Shield Valve
VT Variable Temperature
MOV Motor Operated Mixing Valve
RS Room Sensor
BC Boiler Controls
SP System Pump
TA Standard Sensor
TD Room Sensor with identical features of
TM, along with floor sensor
TIV Thermostatic Inlet Valve
TM Room Sensor with four modes Auto, Day,
Night and Frost protection
TMV Thermostatic Mixing Valve
TP Tamper Resistant Sensor
TRV Thermostatic Radiator Valve
ZV 2-port Zone Valve

5
PRINCIPLES OF UNDERFLOOR HEATING/COOLING
PRINCIPLE OF UFH
Thermal Comfort
REHAU underfloor heating system operates on
the basis of low surface temperatures and even
temperature distribution across the whole floor
with comfortable radiant energy. In contrast to
other heating systems the radiative equilibrium
between occupants and the surfaces in a room
is established and an optimum level of comfort
is achieved.
Energy-saving
Due to the REHAU underfloor heating systems’ high
proportion of radiant energy, comfort conditions can
be achieved with lower room temperatures typically
1ºC to 2ºC. This facilitates a typical annual energy
savings of 6% to 12%.
Environmentally friendly
Due to the high heat output, even at low flow
temperatures, the REHAU sub-surface heating
systems are ideal for use in combination with gas
condensing boilers, ground source heat pumps or
thermal solar power systems.
Good for allergy sufferers
Through the REHAU underfloor heating systems’
low proportion of convective energy only a minimal
thermal vortex is formed. Dust circulation and the
carbonising of dust are thus a thing of the past.
This protects the airways - not just those of allergy
sufferers.
Visually attractive rooms without radiators
The REHAU underfloor heating / cooling systems
- Allow the user to be free with their
interior design
- Gives the architect the planning freedom
- Totally eliminates risk of injury and burning from
surface mounted heat emitters. Hence totally
suitable for nurseries, schools, hospitals, clinics etc.
- Lower maintenance costs.
Operative Temperature according to CIBSE*
Winter Summer
In living spaces and lounges 22-23ºC 23-25ºC
In bathrooms 20-22ºC 23-25ºC
* CIBSE Guide A, Environmental Design
Room air temperatures according to
BS EN 12831
- In living spaces and lounges: 20ºC
- In bathrooms: 24ºC.
Surface temperatures
Maximum permissible floor surface temperatures
are to be observed for the surface as a surface
in direct contact with people for medical and
physiological reasons:
- Occupied zone 29ºC
- Peripheral zone 35ºC (generally situated along in
the floor near large glazed areas).
1.0
1.1
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42,
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1. Thermal comfort, dependent on the room air temperature TRL and the temperature of the surfaces
enclosing the room TF
Red - warm uncomfortable Orange - comfortable
Yellow - still comfortable Blue - cold uncomfortable
Exemplary temperature profiles in heated rooms
2. Radiator heating 4. Sub-surface heating 3. Ideal heat distribution
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6
PRINCIPLES OF UNDERFLOOR HEATING/COOLING
PRINCIPLE OF UFC
Advantages of a Underfloor
Cooling System
- High level of comfort
- Draughts do not occur
- Low investment costs
- Low annual costs
- Preserves resources
- Unrestricted interior design.
Thermal comfort
The thermal comfort for one person
in a room is determined by:
- The person’s activity
- The person’s clothes
- Air temperature
- Air speed
- Air humidity
- Surface temperatures.
The heat output of the human
body occurs via main three
mechanisms:
- Radiation
- Evaporation
- Convection.
The human body experiences the
greatest level of well being if it
can regulate at least 50% of its
heat output through radiation.
With the REHAU underfloor
cooling system the energy
exchange between people and
cooling surface occurs across
large areas and predominantly
through radiation and thus
provides the optimum conditions
for a comfortable room
atmosphere.
1.0
1.2
Classic air conditioning
systems
Traditional air conditioning
systems overcome the cooling
loads that occur by changing
the air, with the following
negative effects:
- Draughts
- High room air speeds
- Cold supply air temperatures
- High sound level.
This can often result in
uncomfortable air conditions for
the user, also referred to as sick
building syndrome.
Economic disadvantages of
traditional air conditioning units:
- High investment costs
- High annual running costs.
Cooling capacity
The standard cooling capacity
of the REHAU underfloor cooling
system is 50W/m2in accordance
with DIN 4715-1.
The performance estimation was
carried out with:
- RAUFIX system
- Distance between pipes 10cm
- RAUTHERM S 16 x 1.5mm
- Coolant temperature 10K
- Temperature spread 2K.
Under practical conditions, with
- surface temperature of 19-20ºC
- room temperature of 26ºC
values of 35-40 W/m2can be
obtained.
Influencing factors on the cooling capacity
The sub-surface cooling system’s maximum achievable output is
dependent upon:
- floor covering
- pipe spacing
- pipe dimensions
- floor construction
- heat gains
- system
However, each of the factors affects the cooling capacity to a
different degree.
The floor covering and pipe spacing have a substantial impact on
the output of the cooling system.
It is recommended that only stone, tile or slate type floor or
other low resistivity floor coverings are used to maximise the
cooling output
20ºC20ºC
32ºC
Radiation
Min 50%
Evaporation
<30%
Convection
<10%
Heat distribution
<2-5%
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3. The human being’s heat balance
0.5m/s
4. Air temperatures and air speeds with pipe underfloor cooling

7
PRINCIPLES OF CONTROLLING
FLOOR HEATING SYSTEMS (FH)
FIXED FLOW WATER TEMPERATURE (FFT) SYSTEM
A conventional boiler system including radiators and domestic
hot water (DHWS) provides water with a flow temperature in the
region of 80ºC. Water is pumped by a Main (system) pump to the
hot water cylinder and to the radiators, where it loses temperature
and on the return, the water temperature normally stays at around
69ºC. Current standards and regulations for floor heating state
that the surface temperature of a floor must not exceed 29ºC (in
perimeter zones and bathrooms 35ºC). In a traditional underfloor
circuit the flow and return water is mixed via a mixing valve to
achieve a flow temp of between 32ºC-55ºC. This is achieved by
mixing the boiler flow with cooler water from the return of the floor
heating circuits. Once flow set point is achieved the mixing valve
closes to the boiler to stop excess temperature rise.
Commonly there are two main systems in use:
- Fixed Flow Temperature (FFT) system
- Variable Flow Temperature (VFT) system
(also known as weather compensated system).
1.0
1.3
A constant temperature system regulates the amount of warm water
being added from the main system boiler to the water circulating
within the circuits, to maintain the flow temperature in the circuits at
a pre-set level. This constant temperature is mechanically pre-set at a
thermostatic mixing valve (TMV).
It is not possible to influence the mixed water temperature remotely by
a building management system (BMS).
For domestic and smaller commercial applications requiring a
constant temperature system, REHAU offers a small and compact
mixing unit called the compact mixer unit. It is supplied pre-assembled
and is ideal for installations where space is limited.
For larger commercial applications, a traditional system using a 3-Port
thermostatic mixing valve is recommended.

8
PRINCIPLES OF CONTROLLING
FLOOR HEATING SYSTEMS (FH)
ZONE CONTROL
1.0
1.4
The REHAU INTELLIGENT zone control system is a simple electronic
control system that has been specifically designed to
give optimum and accurate control of Floor Heating systems.
Heating/Cooling circuits are connected to a central manifold. Each circuit
will have a thermoelectric actuator (AC) on the manifold operating the
return valve for the circuit.
In heating mode:
The heat output in each room is controlled by a room sensor (RS), which
continuously compares the required room temperature with the actual
room temperature. If the room temperature is too low/high, it will signal
the actuator (AC) to open the return valve of the circuit and allow warm/
cold water to flow through it. (As shown in Fig. 5).
Zone controls give control over local/room temperature by adjusting the
amount of water circulating within individual circuits/ zones.
Adjustments are made dependent upon:
- Continuous temperature readings from each room sensor (RS)
- The end user settings such as room temperature set point and
programmed night set-back periods on the timer
In cooling mode:
The cooling output in each room is controlled by a room sensor
(RS), which continuously compares the required room temperature
with the actual room temperature. If the room temperature is too
high, it will signal the actuator (AC) to open the return valve of the
circuit and allow cool water to flow through it.
1.5 Set Back Mode
A floor heating system switches into set-back mode instead of
switching off completely. This means when you leave the house or at
night, the system allows the internal temperature to drop to a lower
level. Depending on the installed system components, this reduced
temperature level can be set for each room individually or for a group
of rooms.
The pre-set temperature for this mode should be carefully selected,
because if the temperature is set too low the system will require a large
initial input of energy coupled with a long response time to raise the
temperature again.
The set back mode enables the system to respond quickly and
efficiently when heat is required. It can also make it possible to
use a smaller boiler compared to a conventional heating system.
UFH - Manifold
AC
AC AC
HLS
IV
CP
IV
IV
ZV
UFH - Return
UFH - Flow
RT
TMV
AC
RT
RT
RT
Master Controller
5. Individual zone control with FH

9
FIXED FLOW TEMPERATURE CONTROL
REQUIRED COMPONENTS FOR FIXED FLOW TEMPERATURE CONTROL
2.0
2.1
This table should help you in
identifying which components you
need dependent on your choice of
flow temperature control.
More details on each control option
and how they are installed and
electrically wired are given in the
subsequent sections.
Authorised Specialists
Installation, commissioning, maintenance and repairs of all electrical control components shall only
be carried out by trained, competent and qualified specialists in accordance with the national, valid
regulations (Health & Safety, Wiring Regulations, etc) and in compliance with the ordinances stipulated by
the local power authorities.
Sources of Danger
Before opening any component always ensure the system is switched OFF at the main heating system
isolation switch.
To clean the components use a dry towel only.
Never clean the unit with water or other solvents (e.g. spirit, acetone).
Never touch any live component with wet hands.
Designated Application
All equipment explained in the following sections is intended for mixing flow and return water to a suitable
mixed water temperature for use with wet floor heating. Modifications or changes to this equipment are
only permitted with the manufacturer’s approval. The manufacturer does not accept liability for damages
arising from misusing the equipment.
Constant Temperature
Component REHAU Art. No. Compact Mixer Unit
Thermostatic Mixing
Valve Configuration
Compact Mixer Unit 237092 1x No
½" Balancing Valve (BV) + ½" TIV (for outputs up to 12kW) 237102 1x¹ No
¾" Balancing Valve (BV) + ¾" TIV (for outputs up to 18kW) 245130 1x¹ No
Bypass Valve Not supplied 1x 1x
Male iron to copper adapters Not supplied No No
Circulating Pump with 2x isolating valves Not supplied No 1x
Manifold Isolating Valves Incl. with Manifold Not used 2x
High Temperature Limit Stat 225125 Included 1x
2-Port Zone Valve (22mm) for outputs up to 12kW 230426 1x² 1x²
2-Port Zone Valve (28mm) for outputs 12kW to 18kW 230427 1x² 1x²
1) Only one balancing valves required, size depending on output
2) Only one zone valve required, size depending on output

10
FIXED FLOW TEMPERATURE CONTROL
FIXED TEMPERATURE MIXING OPTIONS
2.0
2.2
2.2.1 Compact Mixer Unit
- Only for domestic/light commercial
applications
- For outputs up to 12kW use 1/2" valve set
(not to be used to size primary pipes)
- For outputs between 12 - 18kW use 3/4"
valve set (not to be used to size primary pipes)
- The circulating pump only circulates the
warm water through the circuits. A separate
main system pump is needed to supply the
manifolds with hot water from the boiler.
2.2.2 Working Principle
The compact mixer regulates the main system
flow from the boiler directly into the manifold. It
mixes the high temperature water from the main
system flow (usually required temperature +
70°C), with the cooler water from the FH return of
the circuits to ensure the right temperature. The
thermostatic inlet valve (TIV) allows small amounts
from the main system flow to enter the return
header, where it mixes with the return water from
the circuits. The circulating pump (CP) maintains
an uninterrupted flow of water from the return
header up into the flow header and back into the
floor circuits as long as there is a demand signal
present from any of the room sensors.
The temperature of this mixed flow is measured
by the in-line temperature probe, which feeds
back to the thermostatic head on the (TIV).
The thermostatic head of the thermostatic inlet
valve (TIV) is set to achieve the required design
flow temperature. Once the required design
flow temperature is detected by the in-line
temperature probe it closes the thermostatic
inlet valve (TIV), No further main system flow
is allowed into the return header, until the
measured temperature falls below the design
flow temperature.
The unit also features a high temperature limit
stat (HLS) which is explained later in the section
on Temperature Safety Options.
Manifold Ports
Approximate Length L in mm
2
437
3
492
4
547
5
602
6
657
7
712
8
767
9
822
10
877
11
932
12
987
ca 39
16
UFH Pump
41
ca 65
ca. 105
Compact Mixer
Connector Block
160
High Temperature
Limit Stat HLS
Temperature Guage
Inline HLS Temperature Probe
Additional space of
160mm required to
access inline temperature
probe for thermostatic
inlet valve
Inline Temperature
Prove of TIV
Tee Connector with
Drain Valve
Air Vent
L (see table below)
UFH Manifold
(not included in compact mixer)
Balancing Valve BV
System Return
System Flow
“or æ”
210 ±2
Thermostatic Inlet
Valve TIV
55 80
UFH Flow Header
UFH Return Header
Balancing Valve BV
UFH Manifold
(not included in compact mixer)
“or æ”
“or æ”
UFH Flow Header
UFH Return Header
L (see table below)
Inline HLS Te mperature Probe
Temperature Guage
High Temperature Limit
Stat HLS
Air Vent
160 16
ca.39
Compact Mixer
Connector Block
UFH Pump
Additional space of
160mm required to
access inline temperature
probe for thermostatic
inlet valve
Inline Te mperature
Probe of TIV
Tee Connector with
Drain Valve
55
80
Thermostatic Inlet
Valve TIV
System Flow
System Return
210 ±2
41
ca.65
ca.105
Manifold Ports
Approximate Length L in mm
2
437
3
492
4
547
5
602
6
657
7
712
8
767
9
822
10
877
11
932
12
987
8. Compact Mixer Unit fitted to the left side of the manifold with FH flow header
on top, FH return header on bottom
7. Compact Mixer Unit fitted to the right side of the manifold with FH flow header
on top, FH return header on bottom
6. Compact Mixer Unit

11
Boiler
ZV
Manifold Flow Header
Manifold Return Header
ZV
AV
BPV
PV
TRV LSV
CP
SV
RS
Junction Box BA Controller
Radiator
CT2/R
CT2/HW
Hot Water Sensor
HWS
Hot
Water
Cylinder
CMU
CMU
HWS
CT2/R
CT2/HW
SV
ZV
HLS
AV
BPV
SV
PV
CS
RS
TMV
LSV
TRV
Compact Mixer Unit
Hot Water Supply
Radiator Controller
Domestic Hot Water Controller
Safety Valve
Zone Valve
High temperature Limit Thermostat
Air Vent
By pass Valve
Safety Valve
Pressure Vessel
Cylinder Sensor
Room Sensor
Thermostatic Mixing Valve
Lock Shield Valve
Thermostatic Radiator Valve
HLS
9. Hydraulic layout of REHAU Compact Mixer Unit with ‘S’ plan Integration
2.2.3 Installation
- If a module needs to be mounted onto the left side of the manifold:
- the pump inlet / outlet connections must be
loosened first
- rotate the pump 180ºC
- connections tightened again
- temperature gauge and opposite blanking plug unscrewed
- gauge and plug swapped over and screwed into tee adapter.
- The compact mixer is screwed onto the manifold flow/return
headers. Care should be taken that all connections are securely
tightened
- Balancing valve (BV) and thermostatic inlet valve (TIV) are screwed
onto the opposite ends of the manifold headers. (Balancing valve
(BV) to the FH flow header and thermostatic inlet valve (TIV) to the FH
return header)
- The probe of the thermostatic inlet valve (TIV) should be carefully
inserted into the sleeve in the tee-connector underneath the
circulating pump (CP) (return header).
Fitting
- The compact mixer comes pre-assembled, ready to fit onto the
right hand side of the REHAU manifold. It can be integrated into
an existing radiator system via an 'S' plan type control system.
(As shown in Fig. 9)
Due to the inability of a 3-Port mid position valve to isolate both
system ports i.e. DHW & Radiators, it is recommended that this
type of valve is not used with the Floor Heating system.
The thermostatic inlet valve (TIV) must be fitted onto the
system flow pipework from the boiler, not onto the return
pipework to the boiler.
Required Components Qty
Supplied
by REHAU
REHAU Compact Mixer Unit 1x Yes
REHAU Valve Set 1x Yes

12
2.2.3a Before the system is switched on, the following settings
have to be carried out:
- Balancing valve (BV) set to fully open as per recommendations on
the instruction leaflet supplied with the compact mixer
- Thermostatic inlet valve (TIV) set to design flow temperature
- High limit stat (HLS) set 15ºC above design flow temperature (function
explained in the section 2.2.1 Temperature Safety Options)
- The compact mixer must be in position on the manifold before the
electrical connections can be made
- The pump live (brown) connects to the ‘L’ terminal of the secondary
pump connection inside the control centre
- The neutral wire (blue) connects to the ‘N’ terminal of the secondary
pump connection inside the control centre
- The earth wire (green & yellow) connects to the ‘E’ terminal next to the
boiler connection inside the control centre. (See Fig. 12, see page 16).
If the system is wired correctly, the pump should only run if there is a
demand signal, i.e. a room sensor (RS) activates an actuator (AC).
Circulating Pump
Make Grundfoss 25-60 130 (May Vary)
Overall dimensions 140mm x 95mm x 130mm (H x W x L)*
Voltage 230v
High Temperature Limit Sensor
Make Oreg TT 90
Overall dimensions 90mm x 40mm x 60mm (H x W x L)*
Temperature range +20°C to +90°C
Wiring 1.6m, 3 core flex (0.75mm²)
Balancing Valve
Type Up-and-over ½" or ¾" Female-male
Overall dimensions 60mm x 40mm (H x L)*
Material Brass MS 63 (Body)
Thermostatic Inlet Valve
Material Brass MS 63 (Body)
Temperature range +20°C to +50°C (different range on request)
System pressure 10 bar
Differential pressure 1 bar (for system differential pressures greater
than this, install pressure reducing valves prior to
the thermostatic valve)
Temperature Gauge
Temperature Range 0°C to +80°C
* Dimensions are approximates only
2.2.4 Thermostatic Mixing Valve (TMV)
- Suitable for all applications, below 30Kw. Above this weather
compensation is recommended
- Use the correct size of mixing valve (according to required heat
output: 15kW / 20kW or 30kW)
- The circulating pump only circulates the warm water through the
circuits. A separate main system pump is needed to supply the
mixing valve with hot water from the boiler.
2.2.5 Working Principle
The boiler temperature main system flow enters the thermostatic
mixing valve at 70ºC+ and is mixed with the cooler return water
from the circuits as required.
A circulating pump (CP) circulates water at the required design flow
temperature through the circuits via the manifold flow header every
time there is a demand signal from one of the room sensors. On the
return from the circuits water is taken as required, and mixed with
the main system flow. The remaining water is then routed back to
the boiler.
A wax capsule inside the thermostatic mixing valve (TMV)
expands and contracts with a temperature increase or decrease
of the mixed water inside the valve. The pre-set design flow
temperature on the valve is mechanically transformed into a
pre-stop for the valve position. This means, that no more water
from the main system flow can enter the circuits, once the
correct flow temperature is reached. A so called ‘closed’ circuit
or loop is created between the thermostatic mixing valve (TMV),
the circulating pump (CP) and the manifold with its floor heating
circuits.
If the flow temperature falls below the design flow temperature,
the thermostatic mixing valve (TMV) allows additional water from
the main system to flow into the circuit. The amount of water
added is dependent on the temperature decrease, in certain
cases the thermostatic mixing valve (TMV) can fully open the
main system flow port and fully close the return flow port. This
will result in a quick response from the FH system to sudden
increases in heat demand.
FIXED FLOW TEMPERATURE CONTROL
FIXED TEMPERATURE MIXING OPTIONS
2.0
2.2

13
To improve the response time even further it is recommended
to fit a differential bypass valve (BPV) as close to the
thermostatic mixing valve (TMV) as possible. This can reduce
the time it takes for the hot water from the boiler to reach the
mixing valve.
2.2.6 Installation
Required Components Qty Supplied by REHAU
Correct sized 3-Port Thermostatic
Mixing Valve (TMV)
1x Yes
Circulating Pump (CP) Isolating Valve
of correct size (IV)
1x
4x
No
2x (with manifolds)
Bypass Valve (BPV) 1x No
Fitting
(always read and follow instructions supplied with components)
- Identify on the valve the correct inlets for flow and return water
as well as the outlet for the mixed water
- Connect the boiler flow from the 2-Port zone valve into the inlet
for hot water (identified with an “H” usually on the valve body)
using the compression ring connections
- Connect the collective return from the floor heating to the inlet
for cold water usually (identified with a “C” on the valve body)
using the compression ring connections
- Connect the outlet for the mixed water usually (identified with
“MIX” or arrow on the valve body) to the flow inlet side of the
circulating pump (CP) via the isolating valve (IV)
- Fit the circulating pump (CP) using isolation valves on both ports
of the pump making sure the pump inlet is connected to the
mixed outlet of the TMV and the pump outlet to the flow header
of the floor heating manifold.
Wiring
- The pump live (brown) should be wired into terminal (1) of the
Honeywell high temperature limit sensor (HLS) via terminal (L1) of
connector block. Article No. 225125
- The pump neutral (blue) wire is to be connected to terminal
‘N’ terminal of the secondary pump connection inside the
control centre
- The earth wire (green & yellow) connects to the ‘E’ terminal next to the
main pump connection inside the control centre.
Boiler
CP
TMV
TS
ZV
Manifold Flow Header
Manifold Return Header
ZV
AV
BPV
PV
TRV LSV
CP
SV
RS
Junction Box BA Master Controller
Radiator
CT2/ R
CT2/ HW
Hot Water Sensor
HWS
Hot Water
Cylinder
HLS
HWS
CT2/R
CT2/HW
SV
ZV
HLS
AV
TS
CP
BPV
SV
PV
CS
RS
TMV
LSV
TRV
Hot Water Supply
Radiator Controller
Domestic Hot Water Controller
Safety Valve
Zone Valve
High temperature Limit Thermostat
Air Vent
Temperature semsor (Flow)
Circulating Pump
By pass Valve
Safety Valve
Pressure Vessel
Cylinder Sensor
Room Sensor
Thermostatic Mixing Valve
Lock Shield Valve
Thermostatic Radiator Valve
10. Constant Flow Water Temperature system with ‘S’ plan Integration

14
FIXED FLOW TEMPERATURE CONTROL
FIXED TEMPERATURE MIXING OPTIONS
2.0
2.2
Data Thermostatic Mixing Valves (Fixed Flow 3-Port)
For up to 15kW:
Dimensions : 130mm x 95mm x 43mm (H x W x D)
Outlet temperature setting : 35ºC to 65ºC
Hot water supply : max 90ºC
Temperature stability 9 nominal : ± 3ºC
Flow @ 3 bar : approximately 65 l/min
Body : Cast gunmetal, nickel plated
Internal brass components : DZR brass
Fittings : 22mm compression DZR brass
For up to 20kW:
Dimensions : 130mm x 95mm x 43mm (H x W x D)
Outlet temperature setting : 30ºC to 60ºC
Hot water supply : max 85ºC
Temperature stability 9 nominal : ± 2ºC
Flow @ 3 bar : approximately 65 l/min
Body : Cast gunmetal, nickel plated
Internal brass components : DZR brass
Fittings : 22mm compression DZR brass
For up to 30kW:
Dimensions : 146mm x 139mm x 57mm (H x W x D)
Outlet temperature setting : ambient to 60ºC
Hot water supply : max 85ºC
Temperature stability 9 nominal : ± 3ºC
Flow @ 3 bar : approximately 100 l/min
Body : Cast gunmetal, nickel plated
Internal brass components : DZR brass
Fittings : 28mm compression DZR brass
Differential Bypass Valve (straight)
Dimensions : 90mm x 176mm x 52mm (H x W x D)
Opening pressure settings : 0.1 bar to 0.5 bar
Max operating pressure : 10 bar
Max operating temperature : max 120ºC
Body : DZR brass
Connections : 22mm compression

15
2.2.7 Required Components for Zone Control
Masters/ Add On modules
Quantity
Components REHAU Art. No. Heating Heating/Cooling
REHAU BA 202236-001 No Yes
BA Cooling Kit 202233-001 No Yes
Add On, Module 225115-002 Up to 8 zones: 0x
Up to 14 zones: 1x
Wired Sensors/Controllers
Components REHAU Art. No. Constant Flow Temperature
REHAU CT2 (Programmable Room Sensor) 225108-002 Minimum:1x (same time setting in all zones)
Maximum:14x (different time setting in all zones)
REHAU TP (Tamper resistant sensor) 225109-001 Up to 8 zones: maximum of 7x
Up to 14 zones: maximum of 13x
REHAU TA (Standard Sensor) 225106-001
REHAU TD (Comfort plus sensor, includes floor sensor) 225116-001
REHAU TM (Comfort sensor) 225107-002
REHAU HS (Humidity sensor) 229435-001 No
Actuators 241293-002 Minimum:1x per controlled circuit
Maximum:12x per manifold / controller
Switch fused spur Not supplied 1x
Net Extension kit 202239-001 If the distance between the master and the Add On Module exceeds 0.3m, then net extension kit
is required. This includes 2 connector blocks each with 2 small cables with RJ45 connectors
Wireless Sensors/Controllers
Components REHAU Art. No. Constant Flow Temperature
REHAU RF CT2-RH 202246-001 Minimum:1x (same time setting in all zones)
Maximum:14x (different time setting in all zones)
REHAU RF TP 202253-001 Up to 8 zones: maximum of 7x
Up to 14 zones: maximum of 13x
REHAU RF TA 202251-001
REHAU RF TD 202245-001
REHAU RF TM 202254-001
REHAU RC 202244-001 Minimum: 1x
Maximum: 5x
Communication distance: Up to 30m inside building and 100m line of sight

16
SUPPLY
230VAC BOILER B1 B2
X-Relay SEC. PUMP
VOLT FREE 230VAC
LLL N
N
N
L1N L2
2
1
C
LN
High Limit
Temperature
Stat (HLS)
BA Controller
THERMAL ACTUATORS
1 2 3 4 5 6
L N L L L L LN N N N N
1 2 3 4 5 6
L N L L L L LN N N N N
THERMAL ACTUATORS
7 8
L LN N
7 8
L LN N
SWITCH
EXT.
I O
+ +
TT
LINK
DISPLAY
L YN X
SUPPLY
SENSOR THERMOSTATBUS
+
T
+
T
APP
SENSOR
THERMOSTATBUS
MIXING VALVE
0 - 10V
MIXING VALVE24V AC
+
T
ON
OFF 1 2 3 4 5 6 7 8
C
B
A
9
8
7
6
5
4
3
2
1
0
F
E
D
7
6
5
4
3
2
1
0
9
8
STRING
NUMBER (1-F)
UNIT
NUMBER (1-9)
DIP SWITCH
SUPPLY
230VAC
BOILER
B1 B2 230VAC
LL NN
C1 C2
LN
11. Electrical Connections of Secondary Pump Via High Limit Temperature Sensor
2.2.8 Wiring
SUPPLY
230VAC
BOILER
B1 B2
X-Relay SEC. PUMP
VOLT FREE 230VAC
LL
LNN N
LN
BA Controller (Main Control)
THERMAL ACTUATORS
1 2 3 4 5 6
L N L L L L LN N N N N
1 2 3 4 5 6
L N L L L L LN N N N N
THERMAL ACTUATORS
7 8
L LN N
7 8
L LN N
SWITCH
EX T.
I O
+ +
TT
LINK
DISPLAY
L YN X
SUPPLY
SENSOR THERMOSTATBUS
+
T
+
T
APP
SENSOR
THERMOSTATBUS
MIXING VALVE
0 - 10V
MIXING VALVE24V AC
+
T
ON
OFF 1 2 3 4 5 6 7 8
C
B
A
9
8
7
6
5
4
3
2
1
0
F
E
D
7
6
5
4
3
2
1
0
9
8
STRING
NUMBER (1-F)
UNIT
NUMBER (1-9)
DIP SWITCH
SUPPLY
230VAC
BOILER
B1 B2
X-RELAY SEC. PUMP
230VAC
LL NN
C1 C2
Compact Mixer Wiring to the BA Controller
Compact mixer
connection block
High Limit
Temperature Stat
(HLS)
LN
UFH Circulation Pump
Brown
Blue
Green & Yellow
12. Compact Mixer Wiring
FIXED FLOW TEMPERATURE CONTROL
FIXED TEMPERATURE MIXING OPTIONS
2.0
2.2

17
N
L
SUPPLY
230VAC
BOILER
B1 B2
X-Relay SEC. PUMP
VOLT FREE 230VAC
LLL NNN
L1N L2
2
1
C
LN
2 Port Zone Valve
SL PL
Zone Valve wiring connections
for 230v boiler Switching
SUPPLY
230VAC
BOILER
B1 B2
X-RELAY SEC. PUMP
VOLT FREE 230VAC
LL
LNN N
L1N L2
LNSL PL
Zone Valve wiring connections
for Volt Free boiler Switching
SUPPLY
230VAC
BOILER
B1 B2
SEC. PUMP
230VAC
L
LN N
L1N L2
LNSL PL
Grey wire should taken to the
connector of the volt free
supply and connected
Wires to Pump
and Zone Valve
Wires to Pump
and Zone Valve
Wires to HLS Wires to HLS
See Insets for Zone Valve /
Boiler wiring options
Switch Live To BoilerSwitch Live To Boiler
High Limit
Temperature
Sensor (HLS)
X-RELAY
VOLT FREE
L N
BA Controller (Main Control)
NETWORKBUS
NETWORKBUS
ADD-ON
MODULE
WIRELESS
RECEIVER
RJ45
L1N L2
LNSL PL
13. Electrical Connections from zone valve to boiler Via High Limit Temperature Sensor
The wiring instructions supplied within the
control equipment should be used for correct
wiring. The above wiring diagram is for guidance
only and should not be used as a definitive wiring diagram
BA Controller (Main Control)
THERMAL ACTUATORS
1 2 3 4 5 6
L N L L L L LN N N N N
123456
L N L L L L LN N N N N
THERMAL ACTUATORS
7 8
L LN N
7 8
L LN N
SWITCH
EXT.
I O
+ +
TT
LINK
DISPLAY
L YN X
SUPPLY
SENSOR THERMOSTAT BUS
+
T
+
T
APP
SENSOR
THERMOSTAT BUS
MIXING VALVE
0 - 10V
MIXING VALVE 24V AC
+
T
ON
OFF 1 2 3 4 5 6 7 8
C
B
A
9
8
7
6
5
4
3
2
1
0
F
E
D
7
6
5
4
3
2
1
0
9
8
STRING
NUMBER (1-F)
UNIT
NUMBER (1-9)
DIP SWITCH
SUPPLY
230VAC
BOILER
B1 B2
X-RELAY SEC. PUMP
230VAC
LL NN
C1 C2
FLOW WATER
TEMPERATURE SENSOR
SUPPLY
230VAC
BOILER
B1 B2
X-RELAY SEC. PUMP
230VAC
LL NN
C1 C2
BROWN
BLUE
GREEN/YELLOW
L
N
E
ZONE VALVE
L
N
E
APP
SENSOR
TO BE STRAPPED ON THE PIPE WORK (FLOW) AFTER THE ZONE VALVE
ON
OFF 1 2 3 4 5 6 7 8
X - RELAY
DIP SWITCHES
Ensure that DIP 5 is
turned on and DIP 6 is
turned off to enable the
function of high limit
zone valve
Connections for seperate high limitation to the Master Controller
14. Connecting for separate high limitation to the BA Master Controller
The wiring instructions
supplied within the control
equipment should be used for
correct wiring. The above wiring diagram
is for guidance only and should not be
used as a definitive wiring diagram

18
SUPPLY
230VAC
BOILER
B1 B2
X-Relay SEC. PUMP
VOLT FREE 230VAC
LLL NNN
BA Master Controller (Main Control)
THERMAL ACTUATORS
1 2 3 4 5 6
L N L L L L LN N N N N
1 2 3 4 5 6
L N L L L L LN N N N N
THERMAL ACTUATORS
7 8
L LN N
7 8
L LN N
SWITCH
EXT.
I O
+ +
TT
DISPLAY
L YN X
SUPPLY
SENSOR
THERMOSTAT BUS
+
T
+
T
APP
SENSOR
THERMOSTAT BUS
MIXING VALVE
0 - 10V
MIXING VALVE 24V AC
+
T
ON
OFF 1 2 3 4 5 6 7 8
C
B
A
9
8
7
6
5
4
3
2
1
0
F
E
D
7
6
5
4
3
2
1
0
9
8
DIP SWITCH
SUPPLY
230VAC
BOILER
B1 B2
X-RELAY UFH PUMP
230VAC
LL NN
C1 C2
Link
LN
230V Boiler output signal
BOILER
B1 B2
Potential free
boiler output
signal
Remote start
terminal of
boiler
230V Output signal to
control secondary pump
for UFH system
L
N
Connection from BMS timed output
or external time switch
SWITCH
EXT.
I O
15. Intergrating BMS with REHAU Intelligent Controls
The connections are volt free.
Do not apply a voltage to the
EXT SWITCH as this will damage the unit.
FIXED FLOW TEMPERATURE CONTROL
FIXED TEMPERATURE MIXING OPTIONS
2.0
2.2

19
2.3.3 Dew Point Control
The dew point control of the system is performed by the BA Master Controller coupled with
the Humidity sensors positioned within the index rooms (refer section 4.2). The controller
will calculate the dew point temperature based on the index room temperature and the
% of relative humidity within the index room. If the system has more than one humidity
sensor installed within the control system then the BA Master Controller will operate to
the worst case temperature and humidity conditions. If the cool water temperature flowing
into the floor heating/cooling circuit approaches the dew point temperature (safety factor
of 2°C), the controller will signal the actuators present on the manifold to close the return
valve of the circuits and there by preventing the formation of any condensation.
2.3.4 Installation
Required Components Qty
Supplied
by REHAU
High Limit Sensor
(strap-on or phial pocket/well)
1x Yes
Wiring
No wiring work is required if a REHAU Compact Mixer Unit is used.
All other Systems:
- The pump live (brown) wire should be connected to terminal (1) within the HLS
- The 2-Port zone valve live (brown) wire should also be connected to this terminal
- The live (Brown) wire to the high limit sensor is connected to terminal (C) within the
HLS and must be supplied from the ‘L’ terminal of the sec pump connection inside the
control centre. (As shown in Fig. 13)
Note: Please refer to page 16 for wiring diagram.
Data
Strap on:
Dimensions : 92mm x 48mm x 77mm (H x W x D)
Setting range : 25ºC to 95ºC
Switch type : SPDT
Switching Differential : Adjustable from 4K to 10K
Max Ambient Temperature : 70ºC
2.3.1 High Limit Sensor (HLS)
2.3.2 Working Principle
The sensor of the high limit sensor (HLS)
monitors the mixed flow temperature.
This is a safety device, which should be set to a
temperature of 15ºC above the max. design flow
temperature. In the case of a system malfunction
and the max. design flow temperature being
exceeded, the high limit sensor (HLS) switches
off the secondary circulating pump (CP), and cuts
the power to the zone valve. With the zone valve
closed and the circulating pump stopped, no hot
water can enter the floor heating circuits.
Fitting
(Always read and follow instructions supplied
with components)
- If a REHAU compact mixer unit is used, the high
limit sensor (HLS) is already pre-assembled
- Check high limit is set for 15°C above
required set point
- For all other systems the high limit sensor (HLS)
must be fitted after the circulating pump (CP)
and before the manifold flow header. It should
also be fitted at least 0.3m to 0.5m after the
mixing valve.
Recommended Position for HLS
HLS
IV
CP
IV
IV
ZV
AC
TMV
UFH - Flow
UFH - Manifold
UFH - Return
UFH - Manifold
MOV
HLS TS
IV
CP
IV
IV
ZV
AC
UFH - Return
UFH - Flow
FIXED FLOW TEMPERATURE CONTROL
TEMPERATURE SAFETY OPTIONS
2.0
2.3
16. Recommended Position of HLS (3-Port) valve