I WARM Spooled Kit Installation guide

INSTALLATION

MANUAL

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Contents

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. Configuration of the System . . . . . . . . . . . . . . . . . . 5

4. Preparation for Installation . . . . . . . . . . . . . . . . . . . 8

5. IWARM Floor Heating System Installation . . . . . . .12

6. Turning the System on and Operation . . . . . . . . . .27

7. Advices and Notes . . . . . . . . . . . . . . . . . . . . . . . . . .27

8. Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

9. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

10. Plan of the Premises . . . . . . . . . . . . . . . . . . . . . . . .33

11. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

1. General

Dear Customer!

You have purchased a IWARM 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:

JWe recommend you to buy an IWARM Additional Kit

with a thermostat, temperature gage, protective cor

rugated tube for the temperature gage, and a service

box. This will ensure reliable operation of your IWARM

floor heating system.

Jmake sure that your floor area corresponds to the effi

ciency 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.

Jbefore installing the system make sure it is suitable for

your floor finishing. IWARM system is intended for

floors with ceramic or stone tiles or into grout.

Jplan the installation of your heating cable so that it will

not be damaged during subsequent works.

Jif you do not want to apply tile immediately after your

heating system has been installed, make sure that

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your heating elements will not be damaged during this

time (e.g. cover the elements with cardboard or ply

wood sheets).

Jwe recommend you to use only grades of mixtures

which allow for floor heating.

Jmake sure the element heats before any tiling works

(according to instructions in paragraph 5, pages

19–20, 25).

Jtake care not to displace or damage the cable when

applying tiles.

Jread carefully the restrictions on heating system

installation and operation given in paragraph 8.

These instructions contain IWARM floor heating sys

tem 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.

2. Application

IWARM floor heating system is a universal room elec

tric 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:

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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 follow

ing considerations:

JA heating element nominal power shall be:

— 110–120 W per square meter, min, of free floor

space (IWARM as an additional system).

— 130–150 W per square meter (IWARM as the main

heating system).

JIf IWARM 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, win

ter 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.

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3. System delivery kit

IWARM floor heating system consists of a reel of

heating cable element and assembly tape. A thermostat

is necessary for the reliable operation of IWARM floor

heating system. We also recommend you to buy an

I-WARM Additional Kit with a thermostat, temperature

probe, protective corrugated tube for the temperature

probe, and a service box.

Heating section (IWARM heating system) as well as a

thermostat and a service box (IWARM Additional Kit)

have certificates with their specifications and warranties.

3.1. Heating section

Heating section is a heating cable of a sertain length

with 3 m long installation cable. Connection of the heat

ing cable and installation cable, as well as terminal seal

ing are made in enclosed splicing and terminal cou

plings. These boxes are highly reliable. They are repeat

edly 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.

Heating cables of heating sections are made and test

ed according to high reliability technology. Heating sec

tions approved by Russian Compliance Certificates, Fire

Safety Certificates and Hygiene Certificate.

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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 pro

vides 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 IWARM section properly pay atten

tion 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 connect

ed with the protective shield of the cable. This conductor

has to be connected to the building grounding loop (or

neutral conductor).

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Green Box element

thermostat

terminal blocks

service box

grounding loop

or neutral conductor

Coupling

muff

Heating core terminals

(blue and brown)

Screen

terminal

Termination

muff

Installation wire

(cold lead) Terminal

connections Power supply

220 VAC

Sensor

of temperature

control

circuit

IWARM section

3.2. Prepunched band installation

Prepunched band installation is used to facilitate

heating sections laying out and fixing to the floor sur

face. Pieces of tape are fixed to the subfloor. 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 sus

tained.

With programmable thermostats you can set your own

temperature schedule for a day or a week. We recommend

you to use new IWARM series thermostats.

3.4. Service box

The service box is used to appliance cords when sev

eral 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.

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4. Preparation 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 preparato

ry works.

How to prepare the surfaces to lay out the heating

cable is described below.

JConcrete floor: provide smooth, clean and dry sur

face (preliminary level uneven floor surface with any

smoothing mixture). Use primer to get better floor sur

face. Wait for the floor to dry after the surface treat

ment (according to the instructions for use).

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It is recommended to apply primer

to the surface

The floor surface should be

smooth, clean and dry

JCeramic floor tiles: provide clean, dry and smooth

surface without sharp edges, irregularities and so on.

JWooden 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 recom

mended 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.

JFloor with finishing: previous floor finishing (e.g.

laminates, cork and so on) shall be removed together

with the adhesive layer.

JFinishing (tarbitumen mixture) used as water

proofing: 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 recom

mend you to use high quality mixtures with polymer

plastic additives.

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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 differ

ent 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 nec

essary 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

I-WARM 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 cir

cuit breaker.

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Table 1

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 convenient

ly 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.

Conductor

material

Section,

mm2

Max. load

current, A

Max. total heating

power, kW

Copper

2х1,0 16 3,5

2х1,5 19 4,1

2х2,5 27 5,9

Aluminium

2х2,5 20 4,4

2х4,0 28 6,1

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5. IWARM 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 peri

od you can also call our technicians or regional service cen

ters (see paragraph 12, page 37– 38). Remember that reli

ability 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 effi

ciency 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.

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4. Heating system installation under ceramic tiles or in

cementandsand screed differs. Below are proce

dures for the systems of different purpose.

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It is necessary to keep proper

spacing between the appliances

and, for instance, standpipes and

central heating pipes

а. To install the heating system under tiles it is

necessary:

JTo 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.

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Use an angle grinder

or a slitting tool

to get an even chase

You can use a ∅68 mm

milling tool to bore holes.

JInstall the temperature gage. You will need:

— 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.

— 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.

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Plug the end

of the tube securely

— 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.

JClean away any garbage or dust from the floor.

JFix 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.

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You will not need to break the floor

to replace the temperature gage

You will need a gage location

mark when putting the cable

JMark the beginning of the heating section which

shall be close to the service box and a thermostat

location (within 2.5 m distance).

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Bore a hol Drive in a dowel

Fix assembly tape Assembly tape is applied

JPut 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.

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Fixing cable to the tape

Beginning of cabling

Cabling is finished

— 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 xS) / L,

where Sis the actual area in sq. m on which the

section is laid, and Lis 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, with

out sharp turns or cable tension. Splicing and ter

minal boxes of the section shall be on the floor.

JCheck for damages of the heating section after it

has been installed. You will need to measure heat

ing 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

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I WARM Spooled Kit Installation guide

I WARM Spooled Kit Installation guide

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