GENERAL
Dear Customer!
You have purchased a ORANGE BOX floor heating system. Thank you for your choice. We are sure that our product will meet all your expectations and bring warmth and comfort in your home. Please read the following advices carefully before installing the system:
· We recommend you to buy an ORANGE BOX Additional Kit with a thermostat, temperature gage, protective corrugated tube for the temperature gage, and a service box. This will ensure reliable operation of your ORANGE BOX floor heating system.
· Make sure that your floor area corresponds to the efficiency of the system you bought. Advices on how to choose your system and recommendation for heating cable spacing are given in the Appendix to this instruction. Adhere to the recommended spacing when weaving the cable. Do not allow it to approach together closer than 60 mm.
· Before installing the system make sure it is suitable for your floor finishing. ORANGE BOX system is intended for floors with ceramic or stone tiles or into grout. Plan the installation of your heating cable so that it will not be damaged during subsequent works.
· If you do not want to apply tile immediately after your heating system has been installed, make sure that your heating elements will not be damaged during this time (e.g. cover the elements with cardboard or plywood sheets).
We recommend you to use only grades of mixtures which allow for floor heating.
· make sure the element heats before any tiling works
(According to instructions in paragraph 5, pages19–20, 25).
· Take care not to displace or damage the cable when applying tiles.
· Read carefully the restrictions on heating system installation and operation given in paragraph 8.
These instructions contain ORANGE BOX floor heating system installation and connection rules. Remember that proper and long service of your floor heating system is 99 % depend on its proper installation. Follow the instruction here when installing your floor heating system. You can install the system on your own, or turn to either a qualified electrician or our wiremen.
APPLICATION
ORANGE BOX floor heating system is a universal room electric in floor heating system which can be installed under floors with tile covering (or other decorative flooring) and into grout. This system can operate as:
1. Main heating system in detached buildings including those where there is no any central heating system.
2. Additional (comfort) heating system. Installed together with other heating devices and is intended to give additional thermal comfort.
Heating system power choice is based on the following considerations:
· A heating element nominal power shall be:
o 110–120 W per square meter, min, of free floor
space (ORANGE BOX as an additional system).
o 130–150 W per square meter (ORANGE BOX as the main heating system).
· If ORANGE BOX is used as the main heating system, it shall cover 70 %, min, of total floor space in the room.
Consult your sales manager or service department if you want to use this heating system in your balconies, winter gardens, rooms with many windows, open doorways and arches, or rooms with more than 4 m high ceilings.
Our qualified staff will help you to choose the right system which will ensure sufficient heating in you home.
SYSTEM DELIVERY KIT
ORANGE BOX floor heating system consists of a reel of heating cable element and assembly tape. A thermostat is necessary for the reliable operation of ORANGE BOX floor heating system. ORANGE BOX Kits come with a thermostat, temperature probe, protective corrugated tube for the temperature probe, and a back box, certificates with their specifications and warranties.
3.1. HEATING SECTION
Heating section is a heating cable of a certain length with 3 m long installation cable. Connection of the heating cable and installation cable, as well as terminal sealing is made in enclosed splicing and terminal couplings. These boxes are highly reliable. They are repeatedly tested at the factory.
Sections with different nominal power have different colors and marking to facilitate their distinguishing. Sections specifications and wiring diagrams are given in the Appendix to these instructions.
Cable insulation is made of tough, heat resisting, non flammable Tefzel fluoropolymer. Cable shield is made of aluminum foil reinforced with copper line. The shield provides mechanical and electrical protection and increases heat resistance of the cable. Cable jacket is made of heat resistant, hard PVC.
Heating cables are made of high quality materials by leading polymer producers.
Double conductor cable makes it possible to feed the section from one end only. This facilitates section laying out in the room.
To connect ORANGE BOX section properly, pay attention to installation wire coloring.
Blue and brown wires go to the heating wires and are connected to the thermostat.
Plain conductor with twisted copper wires is connected with the protective shield of the cable. This conductor has to be connected to the building grounding loop (or neutral conductor).
3.2. PREPUNCHED BAND INSTALLATION
Pre punched band installation is used to facilitate heating sections laying out and fixing to the floor surface. Pieces of tape are fixed to the sub floor. The tape has equally spaced fixing lugs to assure equal element spacing.
3.3. THERMOSTATS
A thermostat allows for energy saving, turning on only when the thermal comfort in the room needs to be sustained. With programmable thermostats you can set your own temperature schedule for a day or a week. We recommend you to use new ORANGE BOX series thermostats.
3.4. SERVICE BOX
The service box is used to appliance cords when several heating sections are installed, as well as to facilitate sensor of temperature replacement in case of its defect.
Connections are made in two part terminal blocks.
PREPERATION FOR INSTALLATION
4.1. Floor Preparation
To provide long service life of the floor heating system and to eliminate possible damages to the heating cable during installation works you need to do some preparatory works.
How to prepare the surfaces to lay out the heating cable is described below.
· Concrete floor: provide smooth, clean and dry surface (preliminary level uneven floor surface with any smoothing mixture). Use primer to get better floor surface. Wait for the floor to dry after the surface treatment (according to the instructions for use).
It is recommended to apply primer to the surface
The floor surface should be smooth
clean and dry
· Ceramic floor tiles: provide clean, dry and smooth surface without sharp edges, irregularities and so on.
· Wooden floor: Secure the floor planks, cover with water proof plywood sheets 18 mm in thickness or any other similar material sheets and fix them with screws to provide reliable and stable base. It is not recommended to put plywood sheets onto beams or joists such base will not have necessary mechanical strength. Strong base is important to prevent cracks in the mortar or adhesive mixture. Sharp edges of these cracks can damage the heating cable.
· Floor with finishing: previous floor finishing (e.g. laminates, cork and so on) shall be removed together with the adhesive layer.
· Finishing (tar bitumen mixture) used as waterproofing: shall be covered with no less that 50 mm screed. Put the heating cable onto dry screed (screed drying time is 28 days). Consult the manufacturer if you use any other waterproofing finishing. We recommend you to use high quality mixtures with polymer plastic additives.
4.2. Heating sections layout
Heating sections shall not be located in the places where furniture without legs will be put. Consider placing your heating sections in free from such furniture areas.
Do not use the same section to heat rooms of different types, e.g. bathroom and hallway or kitchen. Also do not use the same section to heat rooms with different floor types. Independent floor heating systems are necessary for such rooms, each with a separate thermostat.
4.3. Wiring and thermostat location
Make sure that the wiring in your room allows for the ORANGE BOX floor heating system extra power consumption. Maximum currents for systems with different ratings are given in the Appendix. Consider additional appliances which could be fed from the same circuit. Find out permissible currents of protective equipment (circuit breakers). Standard wiring according to PUE (Electrical Code, rev. 2001) can withstand the following currents and loads (table 1). We recommend you to connect heating systems with 2 kW total power via separate wiring with an additional circuit breaker.
The heating system shall be connected via a RCD (residual current device) with nominal operative current below 30 mA. This is a small device, which is mounted in an electric board, to monitor electric insulation of your equipment. If the floor heating system is to be installed in wet premises (bathrooms, saunas, swimming pools), the shield of the heating section shall be connected to the supply main grounding conductor, which, in turn, shall be connected with all the metal elements, such as: metal shower trays, metal shower cabin frames and so on. Choose the thermostat location. It shall be conveniently wall mounted not impeding placement of furniture.
Thermostats for heating systems in wet rooms (bathrooms, toilets, saunas, swimming pools) shall be located outside these rooms.
ORANGE BOX FLOOR HEATING SYSTEM INSTALLATION
You can install your system independently following the instructions in this instruction. We recommend you to turn to a qualified electrician though. For quality installation and connection of the system which will ensure its warranty period you can also call our technicians or regional service centers (see paragraph 12, page 37– 38). Remember that reliability of your heating system is 99 % dependent on the installation quality.
To install your system it is necessary:
1. To prepare the room (see paragraph 4.1 of this instruction).
2. To mark the area for the heating section considering
50 mm, min., spaces from the walls and furniture.
Also consider 100 mm, min., spacing between the heating cable and other heating sources.
If few sections are to be put in one room, once again make sure that your floor area corresponds the efficiency of the heating sections. Divide marked out area for installation of the heating sections according to their layout surface.
3. Choose locations for your thermostat and service box (if any), and make mounting holes for them at a height of 30 cm, min., above the floor level, and a groove in the wall to put mounting cables and temperature gage wire in.
It is necessary to keep proper spacing between the appliances and, for instance, standpipes and central
4. Heating system installation under ceramic tiles or in cement and sand screed differs. Below are procedures for the systems of different purpose.
You can use a 68 mm milling tool to bore holes.
а. To install the heating system under tiles it is necessary:
· To chase a groove in the floor to install mounting cable and a temperature gage tube. The floor groove for the temperature gage tube must be 20x20 mm and 50–60 cm, min., length from the wall.
Use an angle grinder or a slitting tool to get an even chase
Plug the end of the tube securely
· Install the temperature gage. You will need:
o To put the temperature gage in a corrugated tube.
The temperature gage shall be inside the tube, next to its one end. The connecting wire shall go out from the other end of the tube.
· Tightly seal the floor end of the tube with the gage to prevent mortar from entering the tube.
o Put the corrugated tube with the temperature gage into the groove and bring it to the thermostat or service box. Bending radius of the tube shall exceed 5 cm. The corrugated tube shall reach the thermostat or service box to allow for convenient gage replacement in case of its damage.
· Make sure you can get the gage out the tube.
· Seal the floor groove with adhesive solution or cement it in.
· After the solution hardened, mark the temperature gage location.
o Clean away any garbage or dust from the floor.
o Fix pieces of assembly tape. They shall be fixed in places where heating sections loops will end (along opposite sides of the area) and with 0.5 m gaps to fasten the section loops in the middle.
· Mark the beginning of the heating section which shall be close to the service box and a thermostat location (within 2.5 m distance).
· Put and fix a heating section. You will need:
To fix heating cable next to the splicing box near the cabling beginning. Bring mounting cable along a wall groove into the service box or to the thermostat location.
· The cable is laid in equal spacing without being overlapped. Laying pitch of the section is constant and can be calculated by formula:
Pitch (cm) = (100 x S) / L,
Where S is the actual area in sq. m on which the section is laid, and L is the section length in m (that is indicated in its Technical Certificate). Reel out the heating cable rather that drop it down from the reel to prevent cable twisting. Make sure that the gage was located between two loops of the heating cable.
Put the cable evenly without intercrossing. Strictly adhere to cable spacing within heated area.
Maximum allowed spacing deviation is ±10 mm.
Minimum allowed distance between cable loops is 60 mm (along no less than 0.5 m stretch). Fix the ends of the cable loops with assembly tape lugs taking care not to damage the heating cable jacket. Loops shall bend evenly, without sharp turns or cable tension. Splicing and terminal boxes of the section shall be on the floor.
· Check for damages of the heating section after it has been installed. You will need to measure heating section resistance between insulated wires of the mounting cable. It shall correspond to the value stated in the certificate of the heating section. After that connect wires of the mounting cable in the insulation and measure resistance between them and a copper conductor without insulation. This value shall be no less than 1x103 Ω. Measure temperature gage resistance – the value shall correspond to the stated in the thermostat certificate value.
· Install the thermostat and service box and make all the electrical connections. Connect the thermostat while power is switched off.
· Shortly (for 1–2 minutes) apply voltage and check for integrity of the system (a LED on the face panel of the thermostat shall light). Turn off the power and do not turn it on until the system is put into service.
· Mark the thermostat, service box, temperature gage and heating section locations on the room plan, as well as the make of the heating section and measured heating section and temperature gage resistance values.
· Cover the floor and the applied heating section with adhesive solution 5–8 mm in thickness. Let the solution dry according to its application instructions.
· After the solution has dried up, check for damages of the heating section and temperature gage according to the recommendations above.
· Fill with mortar the wall groove for thermostat power wires, mounting cables and temperature gage connecting wires.
· Apply ceramic tile using freshly prepared adhesive solution.
· After the solution has dried up, the I-WARM floor heating system is ready to work. Turn it on following the instructions in the thermostat certificate.
б. If the heating system is to be installed in a screed, the installation procedure is as follows:
· Clean away any garbage or dust from the floor.
· If the sections are to be put in a screed, it is recommended to put the sections onto thermal padding, which will allow for 10–30 % electric heating system energy saving. See the Appendix for recommendations on thermal insulation choice.
· Fix pieces of assembly tape. They shall be fixed in places where heating sections loops will end (along opposite sides of the area) and with 0.5 m gaps to fasten section loops in the middle.
· Mark the beginning of the heating section which shall be close to the service box and a thermostat location (within 2.5 m distance).
· Put and fix a heating section. You will need:
o To fix heating cable next to the splicing box near the cabling beginning. Bring mounting cable along a wall groove next to the service box or to the thermostat location.
— Put and fix the heating section with recommended in the Appendix spacing. Reel out the heating cable rather that drop it down from the reel to prevent cable twisting. Make sure that the gage was located between two loops of the heating cable. Put the cable evenly without intercrossing. Strictly adhere to cable spacing within heated area. Maximum allowed spacing deviation is ±10 mm. Minimum allowed distance between cable loops is 60 mm along no less than 0.5 m stretch. Fix the ends of the cable loops with assembly tape lugs taking care not to damage the heating cable jacket.
Loops shall bend evenly, without sharp turns or cable tension. Splicing and terminal boxes of the section shall be on the floor.
· Install a temperature gage. You will need:
o To put the temperature gage in a corrugated tube.
The temperature gage shall be inside the tube, next to its one end. The connecting wire shall go out from the other end of the tube.
· Tightly seal the floor end of the tube with the gage to prevent mortar from entering the tube.
· Fix the sealed end of the tube between the cable loops at 50–60 cm from the wall, and fix it between assembly tape lugs.
· Bring the tube from the service box or thermostat location to the floor (bending radius of the tube shall be no less than 5 cm). The end of the tube with the gage inside shall be on the floor, 50–60 cm from the wall, between the loops of the heating cable. We call your attention to the fact that the tube end with the connecting wire shall reach the service box or thermostat, otherwise you will have to break the floor or wall to replace the gage.
· Bring the mounting cable into the service box or to the thermostat and fill in the wall groove with mortar.
· Install the thermostat and service box and make all the electrical connections. Connect the thermostat while power is switched off!
· Check for damages of the heating section after it has been installed. You will need to measure heating section resistance between insulated wires of the mounting cable. It shall correspond to the value stated in the certificate of the heating section. After that connect wires of the mounting cable in the insulation and measure resistance between them and a copper conductor without insulation. This value shall be no less than 1x103 Ω. Measure temperature gage resistance
· The value shall correspond to the stated in the thermostat certificate value.
· Shortly (for 1–2 minutes) apply voltage and check for integrity of the system (a LED on the face panel of the thermostat shall light). Turn off the power again and do not turn it on until the system is put into service.
· Mark the thermostat, service box, temperature gage and heating section locations on the room plan, as well as the make of the heating section and measured heating section and temperature gage resistance values.
· Cover the floor with 3–5 cm mortar (5 cm, min., incase of main heating).
· Let the solution dry according to its application instructions.
· After the solution has dried up, check for damages of the heating section and temperature gage according to the recommendations above.
· Finish with ceramic tiles or apply any other decorative finishing.
· After the solution has dried up, the ORANGE BOX floor heating system is ready to work. Turn it on following the instructions in the thermostat certificate.
o To avoid mechanical damages of the heating cable, installation works shall be performed in shoes with soft, elastic soles, otherwise cover the floor and laid out heating section with cardboard or plywood sheets to prevent mechanical impact when walking on the section.
o Reel out the heating cable rather that drops it down from the reel to prevent cable twisting.
o Keep even spacing when putting several heating sections.
o See adhesive solution drying time in corresponding, application instructions.
o It is possible to apply tile directly onto adhesive solution layer which covers a heating section. Take great care not to damage the heating cable. Adhesive solution depth shall be, min. 8 mm.
TURNING THE SYSTEM ON AND OPERATION
After the mortar or adhesive solution has dried up (see corresponding application instructions), you can turn on the ORANGE BOX floor heating system. Turn the thermostat on and set desirable heating level (see the thermostat certificate instructions). After the floor heating system has been installed, for the first time you can set a maximum heating level. This will quicken floor heating up. When the comfort temperature has been reached, you can turn the heating down to the desirable level.
For the first time the "warm floor" feeling may not appear until after some time.
It is especially applicable to newly built premises without turned on heating. Do not worry and let the system fully warm up the room.
ADVICE AND NOTES
Thanks to automatic temperature regulation, ORANGE BOX system uses as much power as it is necessary to reach a desirable thermal comfort level. Installed in each room thermostats regulate heating process independently, which contributes to energy savings.
I WARM 720 programmable thermostat, which automatically reduces or turns off the heating when it is not necessary, is especially energy efficient. If time of use electricity metering is available, such programmable thermostat allows for maximum benefit. If you have to be away for a long time in cold season, we recommend you not to turn the heating off but set a minimal heating level. In this case the system consumes little power, the premises will not be chilled up completely, and will heat up again more rapidly when you return.
You can get as much as 50 % of energy saving with correct choice of I-WARM floor heating system.
Heating cable shall be put at, min, 50 mm from the walls, furniture without legs and other objects preventing effective heat emission into the air.
When putting the heating cable avoid direct contact of it and heat insulation if the insulation is corrosive, absorbent or inflammable.
Avoid contact with oil, grease and other similar substances when installing the heating cable. Shielded conductor of the mounting cable shall be permanently and securely connected to the grounding clamp in the service box or to the corresponding clamp of the thermostat.
Minimal installation temperature is –5 °С.
YOU’RE SAFTY
o You cannot shorten fabricated heating cable sections or make alterations in the heating section design.
o You cannot change feeding (mounting) cables on your own breaking manufacturer made connections in a box.
o You cannot make any alterations in the thermostat design.
o You cannot, even temporarily, connect rolled up or spooled heating cable sections to the power supply.
o You cannot perform any installation or repairing works with power turned on.
o You cannot connect heating sections to electrical power lines with improper working voltage (see certificate or packing).
o You cannot use the same section to heat rooms of different types, e.g. bathroom and hallway or kitchen. Also do not use the same section to heat rooms with different floor types. Independent floor heating sections with separate thermostats are necessary for such rooms.
o You cannot use this floor heating set without minimal adhesive mixture layer which would fully cover the heating cable.
o Carefully apply even layer of adhesive mixture along all the floor with the heating section, avoiding air voids around the heating cable which would impede heat emission.
o You shall not cover the floor areas with ORANGE BOX system installed with thermal insulation materials (carpets, blankets and so on).
o You should not drive in nails, dowels or screws in floors with installed heating sections.
In case of violation of any of these requirements, the manufacturer disclaims all the warranty liabilities.
WARRANTY
Our Company provides the 16_years warranty for the Products offered: for heating cables and heating mats. We warrant our Products to be free from defects in materials and workmanship. During the warranty period we obligate to repair the heating section or to deliver the new one to the customer for free, without covering indirect costs, connected with the repairing works or replacement of the heating section in case of strict observing the terms of that Warranty.
Terms of Warranty:
1. Heating sections (mats) are to be used strictly in accordance with the Installation Manual of ORANGE BOX System.
2. In case of any guarantee event the customer is to provide the proof that the Product was installed in accordance with the applicable ORANGE BOX System Installation
Manual:
a. The reason of dissatisfaction of the customer in written form
b. Written description of the Product installation works and the history of operation
c. Filled in Technical Certificate
The customer is also to provide a retail sales receipt or proof of purchase of ORANGE BOX Product. Company retains the right to take a decision on the basis of the submitted documentation or after the preliminary diagnostics of the heating systems by the Company specialists.
The following are not covered by this Warranty:
1. Any incidental or consequential damage, including inconvenience, loss of time or loss of income.
2. Any labor or materials required to remove, repair or replace flooring materials.
3. Any freight or delivery costs related to the Product, the control, or any related flooring or electrical products. There are no warranties which extend beyond the face of this document. Our Company 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.
No agent or representative of our Company has any authority to extend or modify this Warranty unless such extension or modification is made in writing by a Company officer.
Due to differences in building and floor insulation, climate and floor coverings, our Company makes no representation that the floor temperature will achieve any particular temperature, or temperature rise. But our Company does warrant that all Products will produce rated output listed in the Technical Certificate.
Products that have been damaged due to mechanical breakdown, due to incorrect connection or due to disregard of the terms of operating rules and servicing are not a subject to the warranty repairs, replacement or return.
All claims are to be sent to the following address:
Orange Box Controls Ltd
Unit 56
Business & Innovation Center
Wearfield
Sunderland
SR52TA
CHOICE OF HEAT INSULATION
In case of installing the system in cement and sand screed, we recommend you to put a layer of hard heat insulating material (Styrofoam), 30–80 mm in thickness, on a sub floor and then a 5 cm screed. Next, an assembly tape is fixed, and installation works continue as described in paragraph 5 above. Floor cross section:
When I-WARM system is to be installed under tiles, heat insulation is not allowed since it can lead to cracks in the 5–8 mm adhesive solution layer above the heating cable.
