Electric Under Floor Mat Heating System
Installation Manual
Thank you for choosing ultra thin Orange Box under floor mat heating system manufactured by Orange Box Controls Ltd. We are happy to offer you this product which will meet your expectations and bring comfort to your home.
GENERAL
This installation manual contains instructions for installation and connection of Orange Box heating system. Please, carefully read this manual before commencing installation. Make sure that chosen system is suitable for your premise and the size of the area to be covered. Please note that incorrect installation could damage the system, if all instructions are followed, no problems should arise. It is strongly recommended to use a qualified installer.
SYSTEM APPLICATION
Ultra thin Orange Box under floor heating system is an electrical cable system on the basis of heating mat for heat retaining creation. It doesn't require the installation of a screed, because it can be easily laid into thin under tile adhesive layer. It is applicable for all types of premises and can be easily installed both on a new surface or on the existing floor in case of repair works, especially when it is highly important to keep low thickness of floor construction or in the premises with low ceilings. Ultra thin Orange Box under floor heating system is used as comfort heating system in the premises with main heating system installed.
System Delivery Kit
Orange Box under floor heating kit includes:
• Single or Double conductor MHH pp ss heating mat where pp stands for rated power in Watts, and ss stands for mat square, m2;
• Thermostat with temperature probe;
• Corrugated tube for temperature probe placement (1m long).
• Circular back box for thermostat application
Technical descriptions, wiring diagrams and warranty liabilities of heating mats and thermostats are provided.
MHH double-conductor heating mat
Double-conductor heating mat is made of a shielded
twin-core cable, fixed on the fiber mesh. One end of
the heating section are fitted up with cold lead and
reliable coupling which passed factory testing and
sealing end. To differentiate mats according to space
and power output types various cable sheath colors
and markings are used. Specifications of heating mats
are given in the Appendix
(please, refer to paragraph 10.3).
MHH heating mat is manufactured and tested in full accordance with IEC (International Electro technical Commission) Global Quality Standards. High reliability of mats is ensured by ultra-thin screened cables with diminished effect (linear power), which are fixed on the mesh with constant wire spacing. Rated linear power of cables used in mats is lower than in standard cables used for electric under floor heating but power output of each square meter of heating mat is about 140W that ensures highly uniform and efficient heating. Thanks to the cable fixation on the mesh there is no need to adjust the wire spacing and to fix the cable on the floor surface which can by chance lead to the damage of the wire during the process of installation. Orange Box mats are produced out of high-quality materials provided by world leading plastic manufacturers.
MHH heating mat consists of double-conductor heating cable, one coupling, installation wires and sealing end.
Heating conductor and screen are reliably connected with two installation wires, which are designed to connect heating section to thermostat and protective earthing.
For correct MHH mat connection, please, pay attention to coloring of cold leads.
Blue and brown installation wires are connected with heating conductor and are to be connected to the thermostat. Ground bus is to be connected to the earth loop of the building (or to zero wire of power network).
THERMOSTAT
Thermostat is an energy saving device which automatically turns the electric under floor heating system on and off. It applies voltage to heating section only when it is necessary to maintain desired temperature of the system for creating comfortable ambient of your accommodation.
Using programmable thermostat you can set the device to maintain comfort temperature during twenty-four hours or a week period.
Roomstat 110
The most popular thermostat model.
It has modern design, lower weight and smaller
dimensions. It has a separate power switch.
The thermostat is supplied with LED indication
of the electric under floor heating system «ON» state. The device
can be placed in multi socket wall mounted frame.
Provides energy saving up to 30%. Roomstat
thermostat has a maximum load current of
16 amps.
I•WARM 720
Room thermostat with remote floor
temperature sensor.
It is flush mounted. The device allows
to decrease significantly energy consumption
of warm floor by maintaining comfort temperature
only in the preset time intervals when it is really
required by the customer. Large-screen backlit
graphical display, three control buttons.
User-friendly «intuitive» «one touch» interface.
The built-in menu allows to control all functions
of the device.
Multimode thermostat with built-in real-time
block and calendar. Built-in economizer.
The device stores and keeps in memory all the information about the electric under floor heating system that allows customer to control his expenditures not to the expense of comfort. «Intelligent» software allows to determine parameters of heat processes in the premise. The user can
only settle time intervals when he needs heating and the device makes the rest by itself. The additional display features: clock, calendar.
The following temperature maintenance modes can be realized:
а) Constant comfort temperature maintenance.
b) Daily comfort maintenance schedule. At that daily cycle of comfort temperature distribution is realized. The user sets time intervals of the day when he requires warm floor. The device adjusts itself to the premise: determines the existing heat properties and defines by itself the time when the electric under floor heating system should «turn ON» to obtain the comfort temperature exactly at the set time. All the rest time the heating system is turned OFF saving the energy. This program repeats on a daily basis.
c) Weekly comfort temperature maintenance schedule. Weekly temperature distribution cycle. It is similar to «daily» option but you program seven days independently and this cycle repeats each week.
I•WARM 720 thermostat has a maximum load current of 16 amps.
I•WARM 730
Room thermostat with 2 remote
floor temperature sensors and two
zones control opportunity. It is flush
mounted.
This model maintains the set temperature
in accordance with a floor temperature sensor.
Large-screen backlit graphical display, three
control buttons. User-friendly «intuitive»
«one touch» interface. Indication of current
floor temperature, set temperature, ON/OFF
heater condition. Self-diagnostic of electric under floor heating
system with warning caption output. Additional heating control mode without temperature monitoring during each hour.
ON/OFF time is set by user in percentage rating. The user sets the percentage – 10% to 90%. Allows precise power control.
Before Orange Box system installations please, make sure that you chose the system suitable for your premise and desired type of heating (main or comfort heating).
Heating Mat Placement
It is recommend to lay heating sections on the
sub floor area free from fixed furniture. Place
heating mats in the usable area: where you walk,
where heat radiation is effective.
To fit mat to the heated area configuration it is
necessary to cut mesh into fragments. When
cutting take care not to cut or damage the heating
cable. Never allow strips of mesh to overlap. Never
use one and the same mat for heating different types
of premises (e.g. bathroom, hallway or kitchen). It is
not recommended to use the same mat for heating
premises with different floor constructions.
For this purpose independent
mats should be installed along with the thermostats.
If it is necessary to heat balcony, terrace, interior garden,
premises with many windows, open doorways, archways,
premises with ceilings over 4 meter high, please, consult
our manager who will offer you suitable system to heat the
premise required.
Please, make sure that an existing in your premise electrical wiring can power Orange Box system. Please refer the present instruction to see the amperage load for Orange Box heating systems. Take into consideration additional electrical appliances which can be energized by the same circuit. Also specify amperage load of your safety devices.
According to Electric Installation Code
(edition of 2001) standard electrical wiring
withstands the following currents and
appropriate power loads (table 1):
It is recommended to use a separate circuit
and separate safety device to power Orange Box
heating systems with power over 2kW. Orange Box
systems are to be connected via Ground Fault Circuit Interrupter (GFCI) which actuating rated
current doesn't exceed 30 mA. This is a small
device mounted on the panel board which controls safety of your equipment thermal insulation.
When mat is installed in damp premises (bathrooms, saunas, swimming pools), heating mat screen must be connected to earth lead of supply network. To this wire must be connected all available metal parts: metal shower trays, metal frames of shower cabins, etc. Choose thermostat location. It should be installed in the most convenient place so it will not interfere with furniture disposal.
Thermostats controlling heating in damp premises (bathrooms, toilets, saunas, swimming pools) must be installed outside of such premises.
ORANGE BOX SYSTEM INSTALLATION
Using this Manual you can install Orange Box
heating system by yourself. We strongly
recommend to entrust connection and powering
to a qualified electrician. High quality installation
and connection of the system ensuring its warranty
period can be performed by skilled specialists.
Remember that heating system durability is 99%
dependent upon its installation quality.
Here you will find description and illustration of
ultra-thin heating mat installation process. If you
need to heat a non standard premise, please consult our manager.
Step by step I_WARM heating system installation:
1. Prepare the space on the wall for thermostat mounting.
2. Chisel out channels for power supply wires, mat cold leads and temperature sensor in the wall.
3. Chisel out 20x20mm long channel in the subfloor for floor sensor with connection wire placed in the corrugated tube.
4. Sub floor preparation: the floor should be even, secure, flex free, with appropriate bearing capacity. The surface must be dry, clean and free of grease, dust and sharp pieces.
5. Place temperature sensor into the tube, which is included in the I-WARM heating kit. The sensor must be placed inside the tube close to its end. Its connecting wire must be exposed from the opposite end of the tube.
The end of the tube with the sensor must be sealed to avoid ingress of cement mortar inside.
Place the tube with sensor in the chiseled channel and lead to the thermostat or to the terminal box. Tube bending radius must be 5cm minimum.
When corrugated tube is affixed to the wall and the floor, make sure that the sensor floats inside the tube.
For this partially pull out and then insert back sensor connection wire.
This installation method allows sensor replacement without removing flooring material.
Attention: The tube end with sensor connection wire should ends at terminal box or thermostat, otherwise it will be impossible to replace sensor without removing floor covering.
10. For single-conductor mat it is necessary to put cold leads to the thermostat via channels chiseled in the wall. Make sure there are no wire break offs. To check
the heating mat and temperature sensor was not damaged during the installation resistance reading of heating mat and temperature sensor should be taken. This reading should conform to their passport data.
6. Fill in chiseled channels with tile7. Mark out area on the sub floor where
the sensor will be fitted.
8. It is recommended to prime the
subfloor with deepened grounding solution.
Intensive absorbing surfaces should
be primed twice. Let the surface get dry.
For double-conductor mat it is necessary to put cold lead to the thermostat via channel chiseled in the wall. Make sure there are no wire break offs. To check the heating mat and temperature sensor was not damaged during the installation resistance reading of heating mat and temperature sensor should be taken. This reading should conform to their passport data.
11. Sketch on the premise plan the
diagram of heating mat, couplings and temperature sensor location.
9. Lay heating mat with mesh adhesive
downside on the sub floor. Make sure that
floor temperature sensor is centered
between two heater wires.
16. Lay ceramic tile using new pre_
pared adhesive solution. Maximum thermal resistance between heating mat andthe premise produced by adhesive layer
and ceramic tile should not exceed
0.06 m2K/W. Ceramic tile covering thickness shall be 5 mm minimum.
17. When tile adhesive solution is fully
dry Orange Box ultra-thin under floor system
is ready for operation. Turn it on following
instructions of thermostat manual.
• Drying tile adhesive solution time is
determined by instruction manual of tile adhesive used.
• Tiling directly onto the heating mat is possible. Be careful not to damage the
heating cable. Adhesive layer thickness
shall be 8 mm minimum.
• Heating mat shall be installed minimum 100 mm away from other heating appliances, e.g. risers and tubes of water heating system.
12. Pour tile adhesive solution onto
the mat leveling the solution from
5–8 mm and let it get dry according to
the manual of preparation and application
of tile adhesive used. We recommend
using tile adhesive for electric under floor
heating systems. Its preparation and
application instructions are given in
paragraph 10.4.
13. When tile adhesive is dry it is necessary
to check whether heating mat or
temperature sensor was damaged during
installation, resistance reading of heating
mat and temperature sensor should be
taken. This reading should conform to
their passport data.
14. According to Technical Certificates
of mat and thermostat connect thermostat
to the heating mat, and to temperature
sensor; connect electric power to the
thermostat; perform earthing.
15. Fill in with tile adhesive channels
chiseled in the wall which leads connection
wires, earth circuit, cold leads of the
heating mat, temperature sensor connection
wires in corrugated tube to the thermostat.
SYSTEM SWITCHING AND OPERATION
Orange Box electric under floor heating system can be turned on when tile adhesive is fully dry. Switch the thermostat on and set the desired level of heating, using instructions of its Technical Certificate. During the first turning on of electric under floor heating system you can set the maximum heating level. It will accelerate floor heating.
When the temperature gets to comfort level, reduce heating level as desired.
When the system is turned on for the first time, the «warm floor» feeling will appear in some period of time. Mainly it concerns new build unheated premises.
Please do not worry and let the system heat your premise. Bear in mind that Orange Box electric under floor heating system refers to comfortable heating type, it might not have enough power to heat cold premise when basic heating system is off.
HINTS AND NOTES
Due to automatic temperature regulation Orange Box system consumes exactly as much energy as it is necessary to maintain comfort level of heating. Thermostats installed in each room control heating independently that allows energy saving. I•WARM 720 is a programmable thermostat which especially allows energy saving for it automatically reduces or turns off heating when it is not necessary. The thermostat is more profitable in case of double-rate payment.
If your premise stays empty in the cold season it is recommended not to turn off the system completely setting the thermostat on the minimal level. In this case the power consumption will be minimal and the room will not be chilled completely so you could heat it quickly upon return. Correct choice of I-WARM electric under floor heating system will allow you to reduce heating costs up to 50%. Heating mat must be placed minimum 30mm away from walls, fixed furniture or other items preventing effective heat radiation. During heating mat installation avoid direct contact with thermal insulation if it is of corrosive, hygroscopic, or flammable type.
During the installation heating mat should not be exposed to oil, lubricant or similar substance influence. Braided shield of the mat cold lead must be securely connected to earthing terminal in the junction box or to adequate thermostat terminal. To avoid mechanical damage of the heating mat perform installation wearing soft elastic sole shoes or cover the mat surface with plywood boards or other material preventing heating cable damage when walking on it. Minimum mat installation temperature is 5 C°.
WARRANTY CERTIFICATE
ORANGE BOX 16 YEAR WARRANTY
ORANGE BOX 16 YEAR WARRANTY DOES NOT EXTEND TO THERMOSTATS, WHICH ARE COVERED BY A ONE YEAR GUARANTEE FROM THE DATE OF ORIGINAL PURCHASE.
This 16 Year ORANGE BOX applies:
1. Only to the original homeowner(s) from the date of purchase.
2. Only for the duration of the Lifetime of the floor covering under which it was originally installed if the purchaser of the heater remains the owner of the residence in which it was installed. If the original purchaser sells such residence, the warranty will transfer and continue for the duration of the16 years from date of purchase.
3. Only if the heater has been grounded and protected by a GROUND FAULT CIRCUIT INTERRUPTOR (GFCI) at all times.
COVERAGE
1) The warranty period begins on the date of purchase.
2) ORANGE BOX under floor system is guaranteed by ORANGE BOX LTDto be free from defects in materials and workmanship under normal use and maintenance for sixteen (16) years, provided the Product is installed in accordance with the accompanying ORANGE BOX installation manual, any special written design or installation guidelines by ORANGE BOX for a particular project, the National Electrical Code (NEC) and all applicable local building and electrical codes.
3) Provided ORANGE BOX heaters are installed under ceramic tile, marble and
natural stone surfaces.
4) During the period of Warranty, ORANGE BOX will arrange for the heater to be
repaired or (at its discretion) have parts replaced free of charge. The costs of repair or replacements are your only remedy under this Warranty. Such cost does not extend to any cost other than direct cost of repair or replacement by ORANGE BOX and does not extend to costs of relaying, replacing or repairing any floor covering or floor.
5) If ORANGE BOX determines the repair of the product is not feasible; we will replace the product with equal or similar features and functionality at ORANGE BOX sole discretion. ORANGE BOX MAXIMUM LIABILITY IS LIMITED TO THE ORIGINAL PURCHASE PRICE OF THE HEATER MULTIPLIED BY THE PERCENTAGE OF THE WARRANTY PERIOD REMAINING.
EXCLUSIONS
ORANGE BOX shall in no event be liable for incidental or consequential damages, including but not limited to extra utility expenses or damages to property. This
Warranty is null and void if:
1) The floor covering over the heater(s) is damaged, lifted, replaced, repaired or covered with subsequent layers of flooring.
2) The heater fails due to damage caused during installation or tiling, unless damage is caused directly by an employee of ORANGE BOX. It is therefore essential to check that the heater is working (as specified in the installation manual) prior to tiling.
3) Damage as a result of floods, fires, winds, lightning, accidents, corrosive atmosphere or other conditions beyond the control of ORANGE BOX.
4) Use of components or accessories not compatible with ORANGE BOX heaters.
5) Parts not supplied or designated by ORANGE BOX.
6) Damage or repair required as a result of any improper use, maintenance, operation or servicing.
7) Failure to start due to interruption and/or inadequate electrical service.
8) Any damage caused by frozen or broken water pipes in the event of equipment failure.
9) Changes in the appearance of the product that does not affect its performance.
If ORANGE BOX is required to inspect or repair any defects caused by any exclusions referenced above, all work will be fully chargeable at ORANGE BOX inspection and repair rates then in effect.
ORANGE BOX DISCLAIMS ANY WARRANTY NOT PROVIDED HEREIN, INCLUDING ANY IMPLIED WARRANTY OF THE MERCHANTABLE OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
ORANGE BOX FURTHER DISCLAIMS ANY RESPONSIBILITY FOR SPECIAL, INDIRECT, SECONDARY, INCIDENTAL, OR CONSEQUENTIAL DAMAGES ARISING FROM OWNERSHIP OR USE OF THIS PRODUCT, INCLUDING INCONVENIENCE OR LOSS OF USE. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE FACE OF THIS DOCUMENT. NO AGENT OR REPRESENTATIVE OF SST LLC HAS ANY AUTHORITY TO EXTEND OR MODIFY THIS WARRANTY UNLESS SUCH EXTENSION OR MODIFICATION IS MADE INWRITING BY A CORPORATE OFFICER. DUE TO DIFFERENCES IN BUILDING AND FLOOR INSULATION, CLIMATE AND FLOOR COVERINGS, SST LLC MAKES NO REPRESENTATION THAT THE FLOOR TEMPERATURE WILL ACHIEVE ANY PARTICULAR TEMPERATURE OR TEMPERATURE RISE.
TERMS AND CONDITIONS
Shipping Discrepancies:
Incoming materials should be inventoried for completeness and for possible shipping damage. Any visible damages or shortages must be noted prior to accepting the material. Any discrepancy concerning type or quantity of material shipped, must be brought to the attention of your I-WARM reseller within 15 days of the shipping date entered on the packing slip for the order.
Miscellaneous:
The terms of this Limited Warranty are exclusive and super cede any other warranty or terms and conditions relating to the subject matter whether included in a purchase order for this product or in any other document or statement.