Undertile Heating Mat. Instructions. CORGI Underfloor Heating - Quality, Flexibility, Safety 1

Transcription

1 Undertile Heating Mat Instructions CORGI Underfloor Heating - Quality, Flexibility, Safety 1

2 It is vital that you read through these instructions fully before installing your CORGI undertile heating mat. Index Technical details 3 Basic wiring information 4 Do s and don ts 5 Calculating heating mat coverage 6 Installation instructions 7 Installing the final floor covering 9 Final electrical connections 10 Warranty information 11 It is important that you check that you have the correct heater or combination of heaters before commencing with your installation, as heaters cannot be shortened or lengthened in any way. CORGI Underfloor Heating accept no liability, either express of implied, for any losses suffered (including consequential losses) as a result of this CORGI Underfloor Heating System being installed in a method that does not follow the installation guidelines contained in this booklet. 2 CORGI Underfloor Heating - Quality, Flexibility, Safety

3 CORGI Undertile Heating Mat Testing You should test your heating mat regularly during your installation with a multimeter to confirm that no damage has occurred. We also recommending testing your heating mat before you unwrap it to confirm you have received it in working order. To test your heating mat you should strip back the black coldtail to expose the live and neutral wires so that your tests can be carried out. Under no circumstances should power be applied to the heating mat to test it before it is fully installed beneath the finished floor covering. You should carry out the following tests and should expect the results detailed below: Live to earth and neutral to earth should show infinity. Live to neutral should show the Ohms value listed in the table below. These tests should be carried out before, during and after tiling over the heating system. If your test results are not as expected you should contact your supplier. Coverage Wattage Output Length in Metres Width Ohms Value +/- 10% 1.0m 2 150W 2m 0.5m 384 Ω 1.5m 2 225W 3m 0.5m 256 Ω 2.0m 2 300W 4m 0.5m 192 Ω 2.5m 2 375W 5m 0.5m 154 Ω 3.0m 2 450W 6m 0.5m 128 Ω 4.0m 2 600W 8m 0.5m 96 Ω 5.0m 2 750W 10m 0.5m 77 Ω 6.0m 2 900W 12m 0.5m 64 Ω 7.0m W 14m 0.5m 55 Ω 8.0m W 16m 0.5m 48 Ω 9.0m W 18m 0.5m 43 Ω 10.0m W 20m 0.5m 38 Ω Technical/construction data Voltage: 240Vac-50Hz Maximum load: 20 W/m Wire type: Dual conductor/single coldtail Maximum Cable Temperature: 90 o C Approvals: CE Marked, BEAB, Semko, 17th Edition Compliant, Low EMC, Manufactured in Western Europe Wire thickness: 3mm Power Range: 150W to 1500W IP Rating: IPX7 as required by the 17th Edition Heating wire construction: Dual Teflon insulated heating elements protected by an aluminium earth shield and PVC outer casing. Approved to: EN :1998, EN :1999, IEC CORGI Underfloor Heating - Quality, Flexibility, Safety 3

4 Basic wiring information Power supplied through an RCD Fused Spur Thermostat 1.3m above floor Floor Mat Floor Sensor A suitably qualified electrician should be consulted to confirm the individual electrical requirements of the project. All systems installation must conform to the most recent electrical regulations (currently the 17th Edition, Section 753). RCD protection must always be included in the circuit supplying power to the heating cable. If the ampage/power of the heating system you are installing is greater than the maximum output of the thermostat you have chosen a suitably rated contactor or similar device will be needed to operate the heating system. The heating cables must never cross each other or come within 30mm of each other. The cold tail join and end connection must be kept straight and should not be bent under any circumstances. They must always be encased within tile adhesive or levelling compound, and must never be covered with tape as this could create air pockets which can cause the joints to overheat. A. Strong PVC outer insulation. B. Full earth shielding. C. Earth wire. D. Reinforcement material. E. Fluoropolymer coating rated to 200 C. F. Dual resistance heating wires. The back page of this installation manual includes an information label that must be left at the distribution board. It is a legal requirement of the installation that this label is completed and the required information is prominently displayed near the relevant distribution board. 4 CORGI Underfloor Heating - Quality, Flexibility, Safety

5 Do s and don ts Do s You must read these installation instructions from start to finish. If you have had the system in stock for a sustained period of time you should visit to ensure you have the latest version of the installation instructions. You must ensure that the installation complies with section 753 of the 17th Edition Regulations, or later additions if applicable. The installation must be protected by a suitable RCD device (30mA). Do ensure that all electrical work carried out complies with the Building Regulations, current IEE Wiring Regulations. You should regularly check the installation with a multi-meter to check the mats have not been damaged. All heating mats must be connected in parallel not in series. The heating mats should be spaced evenly over the floor to provide a smooth heat profile. All heating cable and joins at either end of the cable must be fully covered with tile adhesive or levelling compound. You should fit thermal insulation beneath your heating system if the floor base is not well insulated. We recommend you should always use a CORGI underfloor heating control to run your CORGI underfloor heating system. All heating cables must be placed at least 30mm away from any other section of heating cable or conductive parts. Don ts You must never cut, shorten, lengthen, strain or cross heating cables. The heating cables should never be laid at an output higher than 250W/sqm (220W/ sqm is the normal maximum we recommend). If the mats are being installed beneath a surface other than tiles or stone you should not have an output greater than 160W/sqm and covered with 12mm of levelling compound. You should never install heating cables at an output less than 130W/sqm if you want an even heat output. Never bend the join between the heating cable and the supply cable. You should never test that the heater is working by powering it up before it is fully covered with tile adhesive or levelling compound and the wet trade has been allowed to dry out. If the ambient temperature is below 5 o C you should place the heating mats in a warm room to allow them to heat up before laying them, otherwise they will be inflexible. CORGI heating mats are not designed to be installed in walls or ceilings. The floor temperature sensor on your thermostat should not be installed near another source of heat, such as a radiator pipe. Once the system has been installed no sections of heating cable or the connections should be visible; all must be covered with tile adhesive or levelling compound. CORGI Underfloor Heating - Quality, Flexibility, Safety 5

6 Calculating heating mat coverage Although it is possible to cover your entire floor we recommend leaving a border around the edge of your room of around 3cm as the heating cables must not touch the walls or kick boards. For smaller rooms we would recommend installing heating mats that cover roughly 90% of the free floor area (which is your floor area after you have deducted any areas where pedestals, kitchen units or floor fixed furniture will be installed). In rooms of 7m 2 and above we would recommend aiming to cover around 95% of your floor area. As an example, if you have a kitchen with 17m 2 of free floor area you should aim to cover roughly 95% of the floor area with underfloor heating mats. 95% of 17m 2 is 16.15m 2 so we would recommend using a 10m 2 mat combined with a 6m 2 to provide 16m 2 of coverage. Once you have checked that the mats you have provide suitable coverage we would recommend planning your installation before starting to lay the mats. You should keep this layout and we would also recommend that you take photos of the mat layout during the installation of your system for future reference. To comply with the latest regulations the thermal resistance (insulation properties) between the heating system and the room must not have an insulation value higher than m 2 K/W. Some typical insulation values for common floor coverings are listed below: Tile, stone and thin vinyl floors are usually up to m 2 K/W. Carpets with a hessian backing and low Tog rated underlay are usually up to m 2 K/W. Parquet and laminate floors up to 18mm thick are normally no more than m 2 K/W. Wood fibre and cork floors and rubber backed carpets or rubber based underlays are not suitable for use with underfloor heating as their insulation value is usually above m 2 K/W. Any material used to cover the heating system should have a density of at least 1,500kg/m 3 to ensure good heat transfer of at least 1W/m K. All normal tile adhesives, levelling compounds and screeds conform to this standard. Thermal insulation A 150W/sqm system is suitable to provide full room heating in well insulated rooms on well insulated floor bases and can provide floor heating in less well insulated rooms. If the room or floor base that the system will be installed on is badly insulated we recommend that you consider installing a concrete faced thermal insulation board directly beneath your underfloor heating system. Insulation installed directly beneath a heating system will reduce the warm up time of the heating and also reduce its running costs. Systems installed onto badly insulated floors may not meet your expectations. 6 CORGI Underfloor Heating - Quality, Flexibility, Safety

7 Installation instructions Floor preparation Before laying your system you must ensure that the sub-floor is firm, level and free from dust and dirt. The floor should be swept to remove any loose dirt or dust and a de-greaser should be used to remove any oil patches. Wooden floors should be reinforced with a suitable backerboard or concrete faced insulation board. The floor construction should be uniform over the floor to ensure an even warm up time. If the floor surface is not uniform we recommend laying a backerboard or insulation board over the entire floor before installing the heating system. The sub-floor should be insulated to the current building regulations and, if it is not, we recommend you consider installing additional insulation boards before laying your system. Insulation boards must be concrete faced and should be fully secured to the floor. You should prime the floor first before laying your heating mat and the primer should be checked for compatibility with your chosen tile adhesive or levelling compounds. The primer will help the double sided tape (used to secure the mat) to stick to the floor. Installing your CORGI undertile heating mat We recommend that you wear soft soled shoes whenever walking over CORGI underfloor heating mats and avoid walking on the actual mats as much as possible. Each mat must be tested with a multi meter before unpacking to ensure that it has reached you in good condition. First you should draw a plan of how you intend to fit your mats and this will allow you to ensure that you have the right combination for your room. We suggest starting to roll out your first heating mat from the base of the thermostat (so that the electrical connections will be simple to make) and the mat should have the protective fibreglass mesh on the top side. Once the heating mat reaches a wall you should cut the mesh from side to side between a cable run (carefully avoiding the heating cable), and then you can turn the mat back on itself so it can run in the opposite direction. If you have particularly small or complicated areas you can strip the heating cable from the protective mesh and lay it down onto the floor with double-sided tape. If you are doing this over a wide area you should ensure the cable spacings are similar to ensure an even heat output. Once you are happy with the mats position you can remove the backing from the tapes and use this tape to secure them to the floor base. Any loose heating cable can be secured with masking tape which should be pinched around the cables to avoid air gaps. CORGI Underfloor Heating - Quality, Flexibility, Safety 7

8 Installation instructions It is vital that the heating cables are never less than 30mm apart, and you cannot shorten your heating cables and you must never cross them. During the installation you must ensure that the cold tail join and the end termination are not crushed or bent and are kept flat on the floor. These two sections must be entirely covered with tile adhesive or flexible levelling compound once the installation has been completed and they should not be stuck down to the floor with tape as this can create air pockets which can cause them to overheat. In most circumstances the cold tail connection will have to be chased into the floor to ensure that it does not stand proud once the tiles or other final floor covering are laid. If the cold tail connection is chased into a sub floor of wood or insulation then it is vital that the groove is lined with a flexible tile adhesive before the cold tail connection is laid into it. Masking tape should be used to ensure that any loose heating cable is held firmly on the floor but the tape should not run along the entire length of the heating cable, but should lie across it following the runs of double sided tape and any other areas where the cable is standing proud. Any tape must be pinched around the cable to ensure no air pockets are created. If you are installing multiple mats on a single floor the mats should be laid in parallel (each supply lead will have to go back to the thermostat, connection box or contactor). The floor sensor supplied with your thermostat should be installed halfway between two runs of the heating cable and ideally at least 50cm into the room. The floor sensor should be installed within a length of conduit (closed at the far end) so that it can easily be replaced if required. The floor sensor can be extended if required by up to 20m using a twin sheathed high temperature PVC cable and the connections between the two wires must be fully waterproof and insulated. It is important that the floor sensor picks up the correct floor temperature and for this reason you must make sure it is not close to any other heat source such as radiators or hot water pipes. It is also important to ensure it is not placed in an area where rugs or flat bottomed furniture will later be placed as this will lead to an incorrect reading. Once the installation of the heaters is complete you should check each heating mat with a multi meter before proceeding. If the final floor covering is not going to be laid straight away we recommend covering the heating mats with old carpet, underlay or cardboard and avoiding walking on the system as much as possible. 8 CORGI Underfloor Heating - Quality, Flexibility, Safety

9 Installing the final floor covering It is important to ensure that anyone involved with laying the final floor covering is aware of the heating mats and that if they damage them in any way they should cease laying the floor covering and order a repair kit to make good the cable. Anyone working on the final floor covering should also ensure they are wearing soft soled shoes and they must not cut tiles or stack tiles or adhesive on top of the heating mats as this can damage them. Before the final floor covering is laid the resistance and continuity of each heating mat should be checked. A cursory visual inspection should also be carried out and if there are any nicks in the outer insulation of the heating cable a repair kit should be ordered as over time these nicks can lead to system failure if the cable is not repaired. In normal circumstances we recommend skimming the heating mats with a flexible tile adhesive or flexible screed and letting that go off before laying the tiles or stone. It is important when covering the mats with adhesive or screed to ensure that there are no air pockets left around the cables and cables must always be fully encapsulated. You must not secure the tiles or stones with dabs of adhesive but always use a firm adhesive bed. If the final floor covering will be mosaic tiles, carpets, vinyl or wood coverings a layer of suitable flexible levelling compound roughly 12mm thick should be used. With floors other than tiles it is also important to check with the floor manufacturer that the flooring is compatible with electric underfloor heating. Any levelling compounds, screed, tile adhesive, grouts or glues used to complete your installation must be flexible and fully compatible with electric underfloor heating systems. Please refer to the manufacturer s recommendations to confirm their suitability. If using a flexible tile adhesive a plastic notched trowel should be used to push the adhesive along the cable rather than against it. You should ensure you are careful to prevent any damage to the cables by dislodging them or cutting into them. Ideally use carpet or cardboard to support your weight when working on top of the heating cables. If you have tiled the floor you must ensure that you use a flexible grout to complete the project. You should be particularly careful if any of the grout lines need cleaning out as this is the most common time that heating cables are damaged. If you do need to clean out a grout line you should not use a sharp trowel or anything that could damage the heating cable. Once the floor covering has been laid you should test the heating cables again to check that their readings are all as expected. The heating system must never be used to speed the drying time of the adhesive or levelling compound used to install it and the system must not be powered up until all wet trade is fully dry. CORGI Underfloor Heating - Quality, Flexibility, Safety 9

10 Final electrical connections Once the final floor covering has been installed the final electrical connections can be made by a suitably qualified electrician. All electrical connection work must be carried out to comply with the current IEE wiring regulations and installations must also comply with Part L of the Building Regulations and a Part P certificate should be issued for every installation. It is a requirement of section 753 of the 17th Edition wiring regulations that the floor temperature must be limited for all underfloor heating systems therefore all CORGI underfloor heating thermostats include a floor temperature sensor as well as an ambient air temperature sensor. Please see the CORGI thermostat instructions for further details on the wiring of the thermostat you have chosen. The heating mats will normally be wired directly into the thermostat and the supply cables should be run up the wall in a separate conduit to the floor sensor lead. Up to two heating mats can be wired directly into the back of the thermostat and if there are more than two you should use a suitable connection box. All mats should be wired in parallel, not series. The thermostat must be connected to the power supply via a suitably rated fused spur or circuit breaker and the power supply should also be protected by a suitably rated RCD (in most circumstances 30mA and up to 4.8kW). Should the total power of the heating system breach the level the thermostat is designed for you should run the system through a contactor or similar device and this will allow the system to be controlled via a single thermostat. If the thermostat is placed outside of the room to be heated or inside a cupboard you must ensure it is operating on floor temperature sensor only. Thermal blocking With all underfloor heating systems it is vital to ensure that the system can work to its full capacity without the risk of overheating. Thermal blocking is caused by something on top of the floor preventing the heat from escaping and over a period of time the floor will heat up to a temperature that could damage the heating cable, or the floor covering above in extreme circumstances. Common examples of items that cause thermal blocking include bean bags, rubber backed rugs, furniture without an air gap beneath it and piles of clothes/newspapers on the floor. Thermal blocking is less likely in tiled or stone floors or in situations where the system has been covered with a levelling compound as these coverings are efficient emitters of heat. These types of floor also allow heat to spread out from beneath a thermal block to ensure temperatures do not reach too high a level. Thermal blocking is most likely beneath floor coverings that are less efficient at emitting heat such as carpet, laminate and wooden floors and you should be particularly careful of thermal blocking with these types of floor. 10 CORGI Underfloor Heating - Quality, Flexibility, Safety

11 CORGI Underfloor Heating Warranty Your CORGI Underfloor Heating mat is covered by a 10 Year warranty against eventual defects in materials and workmanship and this warranty is supplied in accordance with Directive 85/374/CEE and relevant national laws. Full details and evidence of defects needs to be presented to CORGI Underfloor Heating or one of out authorised distributors before any warranty claim will be considered. The general warranty does not cover the following situations: Any faults or damage caused to the system due to incorrect installation or misuse. Any system that has not been paid for in full. Any system that is being used for a purpose other than which it has been designed for; namely electric underfloor heating. Any system that has not been installed by a suitably qualified individual or any system for which a suitable Part P certificate is not held. Any system that is not full protected by a suitably rated RCD and fused spur or circuit breaker. Any consequential or subsequent damages including the costs of repairing floor coverings, insulation, professional fees or utility expenses. We will however cover any reasonable damages that were a foreseeable consequence of CORGI Underfloor Heating s negligence. When your warranty is invoked your heating mat will either be repaired or replaced free of charge to you. The repair or replacement of your system is the only remedy available to you under this warranty however none of these warranties affect your statutory rights. CORGI Underfloor Heating will in no way be liable for consequential losses or secondary charges including but not restricted to the cost of replacing floor coverings, professional fees, electricity fees and the fees of tradespeople s subsequent repair work or damage to material items in the property. CORGI Controls Vale Rise Tonbridge Kent TN9 1TB CORGI Underfloor Heating - Quality, Flexibility, Safety 11

12 This document must be filled in and displayed at the appropriate distribution board. WARNING This property is fitted with a CORGI Underfloor Heating system powered by a mains Voltage supply and incorporating 100% earthing. You must not drill into or break up the floor in the rooms with the underfloor heating installed. You must not create any thermal blocking in the rooms where the underfloor heating system has been installed or fit partition walls retrospectively. You should not replace the current floor covering unless you have ascertained that the replacement floor covering is suitable for use with electric underfloor heating. If the floor has been flooded or repairs or alterations are required to the floor in the room where the heating system is fitted please contact CORGI Underfloor Heating for advice. System information Installers details: Signature: Installers contact details Date: Room with heating installed: Total Wattage of system: Please list the product code and test results of each element after installation (compare to install guide for rated resistance) Item Number and Output Resistance Rating Insulation Test Passed This warranty card should be left with the thermostat instruction manual and mat installation guide at the relevant distribution board. The installer must also ensure their layout and wiring diagrams are left with these documents as required by the 17th Edition. CORGI Underfloor Heating CORGI Controls, Vale Rise Tonbridge, Kent, TN9 1TB This installation manual is the work of CORGI Underfloor Heating and the reproduction of any or all of this manual is expressly prohibited without the written permission of CORGI Underfloor Heating or CORGI Controls. Art No