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Underfloor Heating Manifold by LK

LK Underfloor Heating Manifold RF is made of stainless steel, the variants having 1 to 12 floor heating circuits. The manifold is delivered pre-mounted in brackets. The manifold has thermometers on the supply and return, manual air-bleed valves and filling/drain valves*.
(*Manifold RF 1 is supplied without thermometer or filling/drain valve)

LK Manifold RF is made of stainless steel, the variants having 1 to 12 floor heating circuits. The manifold is delivered pre-mounted in brackets. The manifold has thermometers on the supply and returns, manual air-bleed valves and filling/ drain valves.

The upper manifold marked FLOW (supply) is fitted with flow indicators graded from 0,5-5 l/ min and adjustment valves for the adjustment of individual circuit flows. The flow indicators are made of temperature and impact-resistant plastic. The plastic is resistant to anti-freeze, as well as glycol and ethanol with up to 50% mix. The lower manifold marked RETURN has hand actuators for shutting off individual circuits. The hand actuators are normally replaced with LK Actuator, see LK Actuator heading. Primary flow and return can be connected from the left or right-hand sides. The manifold is ready to be connected to the right-hand side on delivery. The connection from the left is done by removing the end cap assemblies. Marking plates for identifying individual floor heating circuits, assembly instructions and a protective bag used to protect the manifold from e.g. splashes of concrete during the assembly period are enclosed.

Settings and values/the flow must be recorded in the self-test document, which is enclosed with instructions for operation and maintenance. There is also a template for self-testing in the installation documents supplied by LK.

General instructions Begin by reading through this assembly instruction and the assembly instructions for the underfloor heating system. LK Ball Valve The supply and return lines on the manifold must be equipped with an isolation ball valve. For more information about the return line, see instructions under the adjustment valve.

Adjustment valve During the laying process involving two or more manifolds, or during connection to a mixed system, all returns from manifolds should be fitted with adjustment valves, e.g. LK OptiFlow Evo II. This is to enable the total flow to the respective manifold to be adjusted correctly. Even during laying involving 1 manifold, the adjustment is made easier if the adjustment valve is fitted. The adjustment valve can be mounted to the manifold, or alternatively to the heat source if there are separate return pipes from the respective manifold.

Adjustment and isolation valves can also be assembled to group manifolds where necessary, e.g. LK Qmax, see separate instructions for group manifold LK Qmax. This is a normal procedure on larger installations.

LK Connection Couplings RF For pipe connection to LK Manifold RF there are compression fittings for LK Under Floor Heating Pipe and LK Universal Pipe in PE-X and PAL for dimensions 12, 16, 20 mm and press connection couplings for dimensions 16 and 20 mm.

Location of LK Manifold RF The LK Manifold is assembled at a designated place according to drawing. If the manifold is to be assembled in LK Manifold Cabinet, see below.

Laying the pipes Lay out the pipe according to the attached installation diagram and mark the circuits with the number and name as per the diagram, use the enclosed marking plates. Begin laying the pipes by connecting the feed pipe to the upper stem of the manifold. Give attention to the direction of the flow in the circuit so that the supply line (outgoing flow) is nearest to the outside wall(s). Pipe bend supports on all pipe is needed up to the connection to the manifold. Pipe decoiler is helpful when laying pipes. Pipe connection with compression fittings To connect the pipes to the manifold first adjust the pipe length, and then assemble the connection coupling according to the illustration below. Lubricate the compression olive. Make sure that the O-rings are not lubricated. Use LK Connection Coupling RF which is made/adapted to the LK Manifold and LK Heating Pipe, LK Universal Pipe and LK PAL-pipe. The insert has an assembled fibre washer to separate the PAL pipe’s aluminium layer from the brass of the pipe insert which could otherwise result in corrosion. Pipes should always be cut with a pipe cutter so that the cut is straight. After a pressure and hot water testing operation with heat, the couplings shall be retightened.

Charging and venting Applies to Manifold RF, 2-12 circuits Before the heating system is filled up you should ensure that the respective floor heating circuit is not affected by the system being filled up, close the supply and return valve for the respective circuit. If necessary, the system can be filled via the manifold’s filling and draining valve. Bleed the heating system sufficiently before filling of the manifold commences.

Execute the steps below for the filling/air bleeding of the floor heating system: #

1. Close the isolation valves to the supply and return pipes to the manifold.

2. The adjustment valves on the upper manifolds should be closed, i.e. screwed at the bottom. Lift of the blue hood and close the valve by hand (tools, e.g. polygrip must not be used).

3. The hand actuator on the lower manifold must also be closed.

4. Connect the water pressure to the filler valve on the upper manifold.

5. Connect the hose to the corresponding valve on the lower manifold. The hose is pulled towards the floor drain or collection vessel.

6. Open the valves on the fill and drain valves. Then gently release the water pressure.

7. First open the adjustment valve which is furthest away from the filling.

8. Then carefully open the corresponding hand actuator on the lower manifold and flush through the circuit until all the air is gone. This is a way of simultaneously checking that the circuits are both correctly connected to the manifold.

9. Then close the hand actuator, first of all, followed by the adjustment valve.

10. Repeat the procedure circuit by circuit until all of them are air-bled.

11. Close the fill and drain valves. Shut down water pressure, disconnect the hoses and screw the walve protective cap.

12. Open the isolation valves towards the supply and return pipes to the manifold and bleed the manifold via it´s manual air bleed valves.

13. Then restore the adjustment valves and hand actuator for the respective circuit.

Sealing test/leak tightness Sealing test/leak tightness of LK Manifold with connected floor heating circuits is carried out as described below.

Tightness testing with water or gas should be conducted in accordance to national regulations. Tightness testing with gas should only occur in exceptional cases as this testing method can involve risks to personal safety. Please note that tightness testing with gas may only be carried out by an accredited/company. Tightness testing is carried out before assembly of any actuators, with all of the valves fully open. Tightness testing should be carried out with 9 bars water pressure. The pressure should be maintained for 30 min, and there after being reduced to 4.5 bar. This pressure will remain for 90 minutes without the pressure being lowered. However, slight variations in the pressure may arise due to changes in the temperature by the medium and surrounding ambient, as well as due to the elasticity of the plastic pipe.

Tightness testing with air, low pressure - A method devised by VVS Företagen (the Swedish Association of Plumbing and HVAC Contractors) and Säker Vatten AB If there is a risk of freezing or bacterial growth before a pipe system is to be commissioned, carrying out tightness testing using water is impractical. Industry regulations Säker Vatteninstallation displays on its website www.sakervatten. se how a simplified tightness test with air can be performed. Note! Under no circumstances may this method be performed with a test pressure higher than 1.1 bar, and it does NOT replace the mandatory tightness test. Carefully follow the document “Förenklad täthetskontroll med luft för vissa rörsystem” (Simplified tightness testing with air for certain piping systems). Use testing protocols, that are available to download from www.sakervatten.se. Note! The system must be depressurized immediately when tightness testing is complete.

Adjustment of the circuit flow Always begin by ensuring that all of the manifold’s return valves are fully open. Then adjust the manifold’s adjustment valves. Lift of the blue hood and adjust the valve by hand (tools, e.g. polygrip must not be used). The adjustment value for each circuit is given from the print out of the LK Calculation Program. The adjustment values are indicated in the number of opening revolutions. In installations where more than one manifold is installed the respective manifold’s total flow should be adjusted after the adjustment of the circuit flows. The adjustment is carried out on the manifold’s group valve LK OptiFlow Evo II (optional), or similar. Begin the adjustment with the manifold which is closest to the circulation pump. The total flow can be identified from the calculation printout from LK. Thereafter the manifold’s circuit flow is fine-tuned with the help of the integrated flow indicators. The indicators have a display range of 0.5 to 5 l/min, in extreme cases the circuit over 5 l/m may be required. In this case you should disregard the flow indicator’s display.

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