prowarm BIG10 Underfloor Heating Cable System Instruction Manual
- May 15, 2024
- prowarm
Table of Contents
UNDERFLOOR HEATING CABLE SYSTEM
INSTALLATION MANUAL
BIG10 Underfloor Heating Cable System
Ultra thin cable
Easy to install
Fully compliant to latest regulations
UKCA & CE approved
Thank you for investing in our industry leading ProWarm™ underfloor heating system
THIS INSTRUCTION MANUAL MUST BE READ ENTIRELY BEFORE COMMENCING ANY
INSTALLATION
This instruction manual contains important information regarding the safe
installation and operation of your heating cable/s.
These installation instructions are not intended to replace or supersede the
installation instructions provided by the manufacturers of your floor
coverings but to supplement them.
Both sets of installation instructions should be complied with, (always check
with the floor manufacturer if you are in any doubt that our heating cable/s
are suitable).
Our cable kits are extremely strong but care must be taken when installing
them, please follow the step by step installation guide to ensure a carefree
installation.
support 01268 567019
UKCA & CE approved systems
Our heating cables are UKCA & CE approved, certified and manufactured to the
highest standards using state of the art Teflon coated cables. All our cables
are designed to be 18th Edition Part P compliant and the instructions we
supply with them include as much information as possible to ensure that all
installations comply with them (please contact us if you are in any doubt).
Before you begin Installing:
Please read through these instructions carefully and check that you have all
the components required.
ProWarm™ heating system is designed for installation below most tile/stone
floor coverings, it may also be installed below engineered/laminate wood
floors, vinyl and low tog thin carpets but in these cases the heating cable/s
must be first covered with an 8-10mm thick suitable latex based levelling
compound
Always check with the floor covering manufacturer for suitability of use with
electric Underfloor heating systems, also check the suitability of any
adhesives/latex compounds that are intended to be used with both the floor
coverings and the heating system.
Items that you will require:
3mm twin-core heating cable on drum(s)
Bottle/s of thermal floor primer
Disposable roller for application of primer
High adhesion fixing tape
Digital thermostat & separate floor sensor
Guarantee Certificate
Conduit for floor sensor
Installation Notes
The system requires a mains voltage 230/240v and must be connected by a
suitably qualified person.
All wiring must conform to lEE 18th Edition Part P regulations.
Our ProWarm™ heating cable/s are 10w per linear metre, total wattage per metre
squared is determined by the spacing of the cable 150watts per sqm is achieved
by spacing the cable at around 6.5cms between the loops. (DO NOT place the
cables any closer than 50mm at any point).
The first part of the cable is the cold tail (coloured black), this carries an
earth screen which is either a solid green/yellow earth cable or a silver
coloured braid which is connected to the main incoming earth from the supply.
The heating cable (red or blue) contains a built in return meaning that the
cable only has to be connected to the thermostat from one end, this cable is
double insulated.
For larger areas, if two or more cables are supplied, it will be necessary to
use a connection or junction box to join the heating cables (cold leads)
together prior to connecting a single cable to the thermostat (Wire used must
be of a suitable size, selected by an electrician). MAX Load on one thermostat
16Amps.
The system is suitable for installing on any sub-floor which is sound and
suitable for tiling, in the main this will be concrete, plywood or cement
faced tile-backer boards. Some water resistant composite boards may also be
suitable, but it is not recommended to tile directly onto hardboard, MDF or
standard grade chipboard as these substances absorb moisture and subsequent
swelling could cause tiles to crack or dislodge.
Please check with installer that the sub-floor is suitable – or please call
our technical advice centre for suitability.
NOTE: if installing on a newly finished concrete screed the required
minimum drying out or ‘curing’ period should be followed before installing
(this is typically 1mm per day in good conditions).
The electrical and electromagnetic fields generated are negligible and well
within all recommended European and International guidelines.
The heating cable MUST NOT be cut or cross at any point.
The joint between the heating cable, cold tail and end joint MUST be located
under the floor and encapsulated in self levelling or tile adhesive and MUST
NOT be taped over.
Professional Electrical Installation
The installation of electrical systems presents risks of fire and electrical
shock which can result in personal injury. Caution should always be taken to
guard against each such risk. Only a qualified electrician should connect the
heating cable/s to the thermostat and / or to the electrical supply circuit.
Carry out all electrical work required to install ie. chase walls and install
back boxes for fused spurs and thermostat position. Please make sure all works
conform to the current regulations.
Caution:
Due to the new requirements of the Part P Regulations, only a qualified
person who is familiar with the construction and operation of the apparatus
and the hazards involved shall make the final connections to the electricity
supply and test the installation.
ProWarm™ Underfloor Heating Systems
Must be controlled via an rcd protected circuit, for systems not exceeding 13 amps a fused spur that has contact separation in all poles that provides full disconnection under Cat 3 conditions can be used, for systems larger than 13 amps a suitable protective device that complies with regulations must be used (please contact us for technical assistance or consult a fully qualified approved electrician). If you are in any doubt about the electrical installation then please contact our technical advice centre.
IMPORTANT
All such connections MUST be in accordance with BS7671 18th Edition Part P
wiring regulations.
Note: When installing heating systems in bathrooms the thermostatshould
always be located outside the room and use the floor probe supplied, always
check with a qualified electrician that all electrics are in safe and in
suitable zones.
Testing
Each and every ProWarm™ cable is carefully tested before it is shipped from the factory and is packed suitably to avoid damage during transit. However, damage does sometime occur in storage or transit, and sometimes during installation. We strongly recommend you test your cable/s:
After unpacking them but before you install them.
After you have installed them but before you install the floor covering (i.e.
while the cable is still exposed).
After installation of the floor covering but before the thermostat is
connected.
A simple test is a visual inspection to make sure there is no visible damage to the heater, and in particular to the cable component in the heater. A simple electrical inspection can be done with an ohm metre to make sure the ohm resistance is what it should be (see page 8). Ohms resistance can vary significantly depending on the ambient temperature and an allowance of – 10% to + 10% from the nominal value is acceptable. At this point an insulation resistance test should now be carried out at 500v DC out by a qualified electrician.
Please see table on page 8 for the values you should see when testing the cable.
Installation Instructions
STEP 1
Ensure that the sub-floor is solid and suitable for tiling, free from dust
and debris. Wooden subfloors should ideally be reinforced to prevent flexing
and the possibility of tiles dislodging.
This can be reinforced using a suitable WBP or Marine plywood or insulated
tile-backer boards such as ProWarm™ Backerboards. Bitumen bases should be
covered with a suitable backerboard or a 3-5mm levelling compound.
DO NOT install the heating cable directly onto a bitumen base.
STEP 2
Prime the floor using the acrylic based primer contained in the kit (not
suitable for anhydrite screeds).
Once primed leave to dry (typically 1-2 hours). Once primed avoid any excess
foot traffic over this area. The purpose of priming is to promote greater
adhesion of the tape and reduce the amount of moisture absorbed into the sub-
floor.
ALWAYS CHECK with tile adhesive/levelling compound manufacturer that the
primer is suitable for use with their product/s, please contact our technical
help centre if you are in any doubt.
STEP 3
If using ProWarm™ tile backerboards or XPS insulation boards, do so in
accordance with the manufacturer’s instructions, we do advise staggering the
boards in a brick bond style and making sure the boards are fixed using
suitable flexible tile adhesive onto solid floors, screws and washers are used
in addition for timber floors fixed at 300mm centres.
(DO NOT use XPS insulation boards on wooden sub-floors)
(DO NOT use ProFoam insulation boards with this heating system)
STEP 4
At this point we recommend referring to the testing procedure on page 6,
please take time to carry this out as it is extremely important.
Resistance Values Twin Conductor 10W / m / 230 VOLTS
Length| Watts| Resistance| | Length| Watts|
Resistance
---|---|---|---|---|---|---
(M)| (W)| (Ohms)| | (M)| (W)| (Ohms)
11.5| 115W| 460.0| | 70| 700W| 75.6
14| 140W| 377.9| | 76| 760W| 69.6
17| 170W| 311.2| | 82| 820W| 64.5
22.5| 225W| 235.1| | 92| 920W| 57.5
29| 290W| 182.4| | 104| 1040W| 50.9
35| 350W| 151.1| | 114| 1140W| 46.4
40| 400W| 132.3| | 125| 1250W| 42.3
48| 480W| 110.2| | 145| 1450W| 36.5
56| 560W| 94.5| | 160| 1600W| 33.1
64| 640W| 82.7| | 180| 1800W| 29.4
STEP 5
Calculate the cable spacing.
IMPORTANT
This is a very important step and MUST be done correctly to ensure all the
cable is used up and avoid extra work later.
First measure the area to be heated in sqm (do not include the area taken up
by fixed objects such as baths/showers and kitchen units), then divide this
area by the length of the cable shown on the drum. The cable is 10 watts per
linear metre so a 750 watt kit contains 75 metres of heating cable. The
spacing is calculated by dividing the total sqm of the area to be heated by
the cable length in metres (see example below).
Example room: 2x3m (6m2) less 0.9 for bath and WC = 5.1m2. Less 10% to allow
for a perimeter leaves 4.6. A cable length of 70m can be used to achieve
150watts per m2 output.
Cable spacing is calculated at 4.6 (room size) divided by cable length 70 =
0.065m (6.5cm) leaving a gap of approx 5-10cms from edge of the room/units.
If in doubt please refer to the Prowarm cable coverage guide online or speak
to one of our advisors on 01268 567019.
Space at 10cm apart for output of 100w per m2
Space at 7.5cm apart for output of 135w per m2
Space at 6.5cm apart for output of 150w per m2
Space at 6cm apart for output of 165w per m2
Space at 5.5cm apart for output of 180w per m2
Space at 5cm apart for output of 200w per m2
STEP 6
Once the spacing has been determined, leaving a perimetre of 5-10cms around
the edge of the room mark out the floor at the calculated intervals. This will
usually be between 5 and 10cms.
If your calculated spacing is less than 5cms STOP and do not install. The kit
size is too big for the room.
A spacing of 10cms will, in many cases, only take the chill off the floor.
Used as a heating source in most domestic situations the spacing should be
between 5.5-7.5cms (this is always dependent on insulation levels and type of
construction).
STEP 7
The heating cable MUST NOT be cut or cross at any point (the heater cable/s
should not be spaced closer than 50mm at any point to each other).
Adjust the spacing if necessary to ensure all the cable is used up and the
floor has an even covering. Tape over the cable at regular intervals ensuring
that it is well secured to the floor.
We do not advise taping over the entire length of wire, as it can create
unnecessary air pockets around the heating wire.
Do not use too much tape as It can also impede the bonding capability of the
levelling compound or tile adhesive.
NOTE: thermostat shown for illustration is to be sited outside the bathroom, please consult qualified electrician if in any doubt of zoning regulations.
COLD TAIL AND END JOINT INSTALLATION
When installing the heating cable you need to be careful with how you install
the end joint and cold tail joint (the join between the supply lead and the
heating mat). They can potentially overheat if the following steps are not
taken.
As the joints on the heating mats are a much larger diameter than the heating
element it is inevitable that you will need to cut a small channel or groove
for them to sit into the subfloor or the insulation board. Once they have been
installed in this groove it is important that you do no cover them with tape
as this will create an air void preventing the joint from dispersing its heat,
this can lead to a potential failure.
The cold tail joint can be secured in place by taping the cable either side of the joint, a small piece on the heating cable and a small piece on the cold tail. This will ensure the joint is NOT covered with tape.
The end joint can be secured in place by taping the red heating element just
before the joint to help secure it in place. This will ensure the joint is NOT
covered with tape. Both these heating joints MUST now be fully encapsulated
within levelling compound and/or tile adhesive.
STEP 8
Check the cable resistance and insulation resistance values after laying.
Check if these values are consistent with pre-install values. Record values on
the guarantee certificate.
STEP 9
Position the sensor in the black conduit supplied between two runs of cable
and tape into position. The sensor wire can be shortened or lengthened. If you
need to cut the sensor wire you must only cut the end containing the wires. DO
NOT cut the end which contains the plastic sensor. The connections to the
thermostat can now be made.
The earth from the cable can then be connected to the earth from the incoming
supply by using the earth terminal in the back box. If using a plastic box
with no terminal then a suitable terminal block can be used.
At this point an insulation resistance test must be carried at 500v DC out by
a qualified electrician. The rest of the thermostat connections can be made
according to the separate instructions provided.
STEP 10
Run the power leads from the start of the cable up to the thermostat
position. If the cable contains a silver earth braid around the cold tail this
can be unbraided by using a screwdriver and pulling down the braid to separate
the strands these can then be twisted into a single strand, this is then
connected to the main earth supply – if the cold tail contains a solid
green/yellow earth then this can connected straight to the main earth supply.
If using multiple cables route all power leads through a conduit from the
floor to a junction box and supply the junction box from the thermostat. The
earth from the cable can then be connected to the earth terminal in the back
box, (shown here) if using a plastic box with no terminal then a terminal
block can be used.
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STEP 11
Test the cable’s resistance again using a multi-meter, an insulation
resistance test should also be carried out to ensure the cable is free from
damage.
STEP 12
If possible cover the cables with a thin layer of suitable latex based
levelling compound (5-6mm). This will help protect the cables when tiling. You
may tile directly over the cables, however extra care must be taken not to
dislodge the cables or to damage the cable in anyway.
If you are using a suitable vinyl/ carpet or engineered/laminate floor as the
final covering then we recommend a minimum of 10mm suitable latex levelling
compound to cover the heating mat/cables to ensure even heat distribution.
You can now lay your flooring according to your floor manufacturer’s
instructions. Please refer to adhesive manufacturer’s guidelines for drying
times before turning on your heating system, this is usually around 7 days,
the floor temperature should be increased gradually by 1-2 degrees per day
over a 2 week period to reduce the risk of force drying. If in any doubt
please check with adhesive/latex manufacturers for advice.
STEP 13
Tile the floor using a flexible tile adhesive and grout as per industry
standards and manufacturers conditions. Finally wait at least 1 week before
turning on to allow time to dry.
NOTE the heating may be slow to react at first, especially if installed
on a new screed floor or in a new building. Start by setting the floor
temperature at approx 18°C – and build up by 1°C per day until your desired
temperature is reached.
Please see separate instructions for connection and operation of digital
thermostat.
Do’s and Dont’s for Installation
| Do read through these instructions carefully before beginning work.
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| Do use flexible adhesives and grouts.
| Do test the cable before tiling.
| Do be careful not to damage or dislodge the cable during tiling.
| Do ensure the cable is spaced no closer than 50mm between loops.
| Do try to protect the cable with cardboard or carpet during tiling.
| Do wait at least 7 days before turning on the system.
| Do read the separate installation and operating instructions for the
thermostat.
| Do ensure the joint between the cold tails and heating cable is beneath the
tiles.
| Don’t attempt to cut the heating cable at any point.
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| Don’t allow the cables to cross or touch.
| Don’t allow excessive foot traffic over the wire before tiling.
| Don’t cut tiles over the heating cable.
| Don’t place tools or stacks of tiles on top of cable.
| Don’t place any product over the floor covering that has a higher tog value
than 2.5.
| Don’t place any bean bags or fixed furniture over the floor covering.
| Don’t place cable closer than 100mm near any pipes.
| Don’t turn on the heating mat/cable while it is rolled up or still on the
drum.
| Don’t tape over the end joint or the cold tail joint
IMPORTANT
Please ensure that the cold tail joint (the join between the heating cable
and flexible supply lead)is fully encapsulated in adhesive or levelling
compound underneath the floor covering.
Please ensure that the end joint (the join at the end of the cable which is
black) is also fully encapsulated in tile adhesive or levelling compound
underneath the floor covering.
Both the cold tail joint and end joint MUST NOT be covered with tape, this can
cause the cable to overheat and eventually fail!
DO NOT BEND THE COLD TAIL JOINT AT ANY POINT
Lifetime Warranty
ProWarm™ floor heating cables come with a full lifetime warranty.
The warranty does not cover installations made by unauthorized persons or
faults caused by incorrect design by others / misuse / damage caused by others
/ damage in transit / incorrect installation and any other subsequent damage
that may occur. Replacement will be fully chargeable if the damage is because
of any of the above reasons.
Please visit website for full terms and conditions.
www.ProWarm.com
Need Help installing your underfloor heating?
Call us on 01268 567019 and we will be happy to help.
CableSafe™ Guarantee
ProWarm™ is the only company that offers you a no quibble exchange on a
damaged cable. If you damage your heating cable during installation then on
receipt of the damaged cable/mat we will send you a new one of the same size
free of charge. Only one cable/mat per Invoice. This amazing free peace-of-
mind insurance is only offered by ProWarm™. No waiting for a repair engineer
to come out and no more expensive mistakes – as soon as we receive your
returned cable/mat we will send you a new one on next working day delivery.
Please visit website for full terms and conditions.
www.ProWarm.com
SAFETY GUIDELINES
This installation manual has been designed for your safety. For a
successful installation please make sure you have understood the guidelines
and adhered to all the instructions
IMPORTANT
Flat bottomed furniture MUST NOT BE placed over areas where the heating
mat/cable is installed as this can restrict airflow to the floor, causing
thermal blocking, and in extreme cases may lead to the cable overheating
causing a possible fire hazard. This also includes rugs, bean bags, or any
item which has a tog value greater than 2.5.
The supplied Commissioning Record MUST BE completed, including a floor plan sketch, to indicate heated areas, which must be permanently fixed in or near the distribution/fuse board as required by the 18th Edition BS7671
| MATTRESSES
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| BEAN BAGS
| ANIMAL BEDS
| RUGS
| FLAT BASED FURNITURE
Installation video
Scan QR code to watch this installation video giving you step-by-step guidance
for a successful installation.
T: 01268 567019
www.prowarm.com
https://www.youtube.com/watch?v=hoVWeTxM_00