PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

R557

SUMMARY

1.
1.
2.
3.
4.
6.
6.
7.
8.
8.
9.

APPLICATION
OPERATING
COMPONENTS
OVERALL DIMENSIONS
APPLICATION EXAMPLE
POSITIONING OF THE HEAD
WITH THERMOSTATIC OPTION
CIRCUITS BALANCING
ACTUATOR ASSEMBLY
EXAMPLE OF ELECTRICAL CONNECTION
PRESSURE LOSS DIAGRAMS
TECHNICAL SPECIFICATIONS

June 2007

ISO 9001: 2000

0131EN

0006/5

IT-3995

PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

Application
During recent years, planning and installation of heating systems has shown a considerable evolution,
due to customer requirements seeking higher environmental comfort by limiting management and
maintenance costs. One of the most popular solutions is the mixed system, where in the same
property radiators are supplied at high temperature and circuits with underfloor heating are supplied
with water at low temperature and used in the same system. The R557 pre-assembled manifold is
particularly useful in these applications, i.e. where the system dimensions are limited and where the
installation of an electronic regulator with the relevant component controls is not used. The mixing
and regulating manifold R557 allows distribution of water at low temperature to the secondary circuit
at a fixed point by drawing off from the primary circuit at a higher temperature, which is necessary for
supply to a towel rail, radiators etc.

Operating
M
S

VD

TS

P
T

D
R

The valve V and lockshield D constitute the connection points to the primary circuit at high temperature.
The valve V receives water at a temperature of 70 80 C, while from the lockshield D a flow similar
to that received through the valve V returns to the boiler at a temperature similar to that of the return
to the underfloor heating system. The R462L thermostatic head T is fitted to the valve body limiting
the range to 20 70 C and is supplied with a sensor S inserted into the upper flow manifold M of the
underfloor heating system. The return water from the underfloor heating arrives to the lower manifold
R where a small part flows towards the lockshield D and consequentially to the return primary circuit,
while the larger quantity drawn from the pump P is mixed with the high temperature water coming
from the valve V. By positioning the thermostatic head T to a prefixed flow temperature for underfloor
heating, we will obtain movement of the valve V allowing the relevant amount of hot water to enter
the inlet of the manifold, depending on the heat load being sufficient to maintain constant flow
temperature.

In order to avoid an unrequired temperature increase of the primary circuit, it is recommended to fit a
security thermostat TS to the R557 manifold which in case of failure will interrupt the pump supply P.
In these conditions water at high temperature is pushed by the pump of the primary circuit (required
for correct operation of the manifold). Arriving from valve V flows from the lockshield valve D without
entering the underfloor heating system as pump P is switched off.
In order to regulate the different circuits of the underfloor heating system, actuators type A thermostatic
head with remote sensors or room thermostats can be fitted to the manifold. The differential valve VD
installed on the manifold avoids pressure changes when the actuators close.

Components
The pre-assembled manifold for underfloor heating systems is supplied with:
- R553S flow manifold with built-in balancing lockshield valves
- R553V return manifold with built-in balancing valves
- R588L adjustable brackets
- R557B T with nut and tail piece
- R557D T with nut and tail piece
- R252 Isolating pump valve
- R462L Thermostatic head temperature limiting with 20 70C field
- R554D self-sealing connection, thermometer, automatic air vent
- R554A self-sealing connection with automatic air vent, differential valve
- R557P tail piece
In order to complete the Group, the following products have to be added according
to the requirements:
- R401TG/R402TG Angle or straight valve or R411TG/R412TG
- R14TG or R15/TG angle or straight lockshield valve or R29TG, R31TG
- R593 Plug with air vent connection of the suitable size, for valve and radiator connection
- K373 Thermostat with immersion temperature sensor, with R227 flow temperature sensor housing
- R179 adaptors for PE-X or Pb pipes, R179AM for multilayer pipes or R178 adaptors for copper pipes
- R473/R478 actuators or R463 thermostatic heads with remote sensors
- Circulating pump having 130/180 mm interaxis
- R500 manifold cabinet, stove enamelled

June 2007

ISO 9001: 2000

0131EN

0006/5

IT-3995

PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

Overall dimensions
If the R557 is supplied with a circulating pump having 130 mm interaxis, the R500 stove enamelled
cabinet can be used. For pumps having 180 mm interaxis (the application of which is limited to certain
circumstances due to the height of the manifold), a suitable cabinet must be made up on site by the
installer.

X
I

PART NUMBER

OUTLETS

R557Y002

18

50

11/2

433-473

274-314

137

130-180

377 116,6

R557Y003

18

50

11/2

433-473

274-314

137

130-180

427 116,6

R557Y004

18

50

11/2

433-473

274-314

137

130-180

100

477 116,6

R557Y005

18

50

11/2

433-473

274-314

137

130-180

150

527 116,6

R557Y006

18

50

11/2

433-473

274-314

137

130-180

200

577 116,6

R557Y007

18

50

11/2

433-473

274-314

137

130-180

250

627 116,6

R557Y008

18

50

11/2

433-473

274-314

137

130-180

300

677 116,6

R557Y009

18

50

11/2

433-473

274-314

137

130-180

350

727 116,6

R557Y010

18

10

50

11/2

433-473

274-314

137

130-180

400

777 116,6

R557Y011

18

11

50

11/2

433-473

274-314

137

130-180

450

827 116,6

R557Y012

18

12

50

11/2

433-473

274-314

137

130-180

500

877 116,6

Application example
The R557 manifold is supplied without thermostatic valves and lockshields, as they should be chosen
in accordance with the requirements of the water flow at high temperature. The quantity of water
circulating in the manifold and consequentially in the circuits of the underfloor heating is not the only
consideration allowing this choice, as it must be related to the radiator outputs and to the difference
in temperature between primary and secondary circuits. It is important to choose the correct size of
thermostatic radiator valve body on the primary flow to ensure accurate flow rates to the system.
This phenomenon happens where the temperature of the primary circuit is not constant and subjected
to wide variations (i.e. wall hung boilers where we have low inertia and limited on-off operations).
In certain cases this phenomenon is so evident that a high level thermostat must be used to close
the pump to avoid relevant operational problems. Otherwise if the valve with thermostatic option is
not of the correct size the start up time will be longer and the system will have limited performance:
in these cases the water velocity to the manifold is increased by the additional flow rate from the
valve with a consequent increase in pressure loss (not always allowed for by the pump of the primary
circuit) and increased noise will be evident.
In order to select the correct sizes of valves with thermostatic option it is necessary to study the
following diagram:

Qp Tm

Qp Tc

Qp Tr

Qp

Water flow for underfloor heating circuits (l/h)

Qc

Water flow from the primary circuit at high temperature (l/h)

Tc

Water flow temperature from the primary circuit at high temperature (C)

Tm Flow temperature to the panel radiator circuits (C)

Tr

Qp Tr

Return temperature from the panel radiator circuits (C)

June 2007

0131EN

ISO 9001: 2000

0006/5

IT-3995

PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

By taking into consideration a constant specific heat and density of water at high temperatures used
in the R557 manifold the following can be expressed
Qp x ( Tm - Tr ) = Qc x ( Tc - Tr )
from this formula the Qc flow is obtained which will select the valve dimension.
Qc = Qp x

(Tm - Tr)
(Tc - Tr)

If for example water temperature of the primary circuit which supplies the manifold is Tc=80C and
the circuit with underfloor heating is calculated with Tm=40C and Tr=35C (then with a difference
of temperature Dt = 5C) for a total flow of the manifold with underfloor heating of Qp=1000 l/h
we will obtain the following.
Qc = 1000 x

(40 - 35)
= 111 l/h
(80 - 35)

With this flow value from the pressure loss diagrams of the valves with thermostatic option, can see
that a 3/8 valve will have a pressure loss of ca. 400 mm water column and a 1/2 valve will have a
pressure loss of ca. 290 mm water column and so it will be suitable for this operation.
If in the previous example we had a water temperature of the primary circuit supplying the manifold
Tc= 55C the water flow entering under the same conditions, the secondary circuit will be
Qc = 1000 x

(40 - 35)
= 250 l/h
(55 - 35)

which in a 1/2 thermostatic valve will have a pressure loss of 1700 mm water columns extreme
for many applications, while in a 1 valve the pressure loss is of 370 mm water columns, admitting
value.
These considerations indicate that in case of high primary circuit temperatures, the water entering
the manifold inlet becomes low and requires the use of thermostatic valves and lockshields of limited
sizes. Otherwise if the primary temperatures are low as i.e. in systems with condensing boilers, the
inlet flow increases and valves with larger dimensions are required.

Positioning of the head with thermostatic option

The flow temperature of the system with

underfloor heating can be pre-determined
by positioning the R462L thermostatic
head according to the values reported in
the following table. Regulation precision
is very high ( 1C ca.) and it is suggested
to proceed with the calibration by making
some adjustments of the head position with
the system. In order to avoid tampering it
is possible to lock the head by using the
setting on the regulation valve, which is
adjusted by key .
Position

T[C]

20

23

34

45

56

67

70

Circuits balancing

The flow manifold has built-in adjustment

with mechanical memory for circuit
balancing. By using R558 key it is possible
to fully open the regulation valve with a
screwdriver and then starting from the
fully closed position, open the lockshields
the number of turns obtained from the
calibration diagrams. After having completed
the balancing, tighten the regulating valve
again on the relative lockshield valves. This
operation will allow to open and close the
circuits without loosing the initial calibration
position.

June 2007

0131EN

ISO 9001: 2000

0006/5

IT-3995

PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

Actuator assembly

R473

If the R557 manifold supplies circuits

installed in the same apartment or house, we
suggest to regulate the room temperature
by installing a thermostat able to directly
control the pump by fitting a simple timer
to limit the on and off switch. If circuits for
heating different rooms are connected to
the manifold, the higher comfort and saving
is obtained by installing in each room (K480
thermostats) connected to R473 or R478
actuators, or to the R463 thermostatic heads
with remote sensors. Our actuators are easily
installed on the return manifold by removing
the valve shut-off cap.

R478

Example of electrical connection

The following scheme shows a typical mixed system where standard radiators at high temperature
are combined with R557 manifold for underfloor heating systems. The electrical system has to be
made by allowing that the pump of the primary circuit is operating when the pump of the manifold
is started and the side at high temperature is working also when the R557 group is switched off.
The scheme has to be followed according to the type of actuator installed and system complexity, by
using suitable electrical components.
Thermostat

Thermostat

Thermostat

R
R

R473
R478

K373

Pressure loss diagrams

Manifold with R473/R478 actuators
1

2000

5 TA

1500

rp [mm H2O]

1000
900
800
700

Opening
turns

Kv

400

0,17

300

0,27

250

0,54

0,83

1,15

TA

1,35

600
500

200

Q [l/h]
8

700
800
900
1000

600

500

400

300

250

200

150

80
90
100

70

60

50

40

30

25

20

15

100

10

150

June 2007

ISO 9001: 2000

0131EN

0006/5

IT-3995

PRE-ASSEMBLED MANIFOLD FOR HEATING SYSTEMS

WITH THERMOSTATIC MIXING

Group with R463 thermostatic heads with remote sensor in D 2C

1

2000

3 4 5 TA

1500

rp [mm H2O]

1000
900
800
700

Opening
turns

Kv

500
400

0,17

300

0,26

250

0,40

0,45

0,51

TA

0,55

600

200

700
800
900
1000

600

500

400

300

250

200

150

80
90
100

70

60

50

40

30

25

20

15

100

10

150

Q [l/h]

Technical specifications
Pre-assembled manifold for radiant systems with fixed point regulation, composed by a delivery
manifold with regulation micrometric lockshield valves, and by a return manifold complete with
micrometric valves with thermostatic option. It is equipped with temperature limiting thermostatic
head and intermediate fittings with discharge cocks.
Max water temperature: 110C.
Max system pressure: 10 bar.

This technical communication has an indicative value. Giacomini S.p.A. has the right to make in anytime, without previous advice, modifications to the products contained in
the present communication for technical or commercial reasons. Information reported in this technical communication does not free the user from scrupulously following the
existing technical instructions. A reproduction, also partial, of the text is forbidden, except for previously written authorisation from the Management.

JUNE 2007 TECHNICAL COMMUNICATION GIACOMINI N 0131EN

IT REPLACES THE TECHNICAL NOTICE N 4-050GB

GIACOMINI SPA
Via per Alzo,39
28017 San Maurizio dOpaglio (NO) ITALY
tel. 0322 923111 - fax 0322 96256
e-mail: [email protected]
internet: www.giacomini.com