caleo BVF Heating Film Instruction Manual
- June 5, 2024
- caleo
Table of Contents
BVF Heating Film
Instruction Manual
INTRODUCTION
Application
The guarantee of top-quality CALEO heating systems is the professional design
and installation services. In order to ensure long-term and reliable operation
of the system, installation of the heating films may only be performed by
professional electric personnel qualified by BFV Heating Solutions Ltd.
As a first step, detailed information shall be gathered from the client
regarding the horizontal and vertical building structures, openings, floor
finishing materials and desired use of the premise. Having all the necessary
data for heat loss calculation and geometrical features of the building, our
colleagues send detailed quotations to the Clients, highlighting the necessary
tasks to perform before installation by the Client as well as details of the
system planned (areas covered, installed heating and necessary electric
capacities, controlling etc.)
How to design
While designing our heating systems, we strongly recommend taking into account
the following factors:
- technical parameters of the building structures
- client’s demand
- Define if primary or comfort heating is required
- Type and thickness of the planned floor finish material in case of floor heating
- Available free height in case of ceiling heating
The appropriate heating capacity is determined – in the case of planning
primary heating – on the basis of the energetic and heat insulation properties
of the building. Heat insulation values of the horizontal, and vertical
structures, openings, climatic location, and desired function to determine the
actual heat loss values and required heating capacities of the units.
The following table illustrates the suitability of certain capacity CALEO film
heaters at different energy loss classified buildings.
| Primary heating| Comfort heating
---|---|---
CALEO| A+ – B
category| B-D
category| worse than
cat. E| B – A+
category| worse than
cat. B
80 W/m2| | | | |
130 W/m2| | | | |
160 W/m2| | | | |
| Floor heating| Ceiling heating
---|---|---
CALEO| REG| DIRECT
80 W/m2| |
130 W/m2| |
160 W/m2| |
Low-capacity film heaters are used for floor heating only. Never use the 160W/m2 and 210W/m2 film heaters in floor structures.
Model| Rated input power| Width (mm)| Rated voltage|
Rated input frequency
---|---|---|---|---
Caleo_EU080030KR| 80 W/m2| 300| 230 V| 50 Hz
Caleo_EU080040KR| 80 W/m2| 400| 230 V| 50 Hz
Caleo_EU080050KR| 80 W/m2| 500| 230 V| 50 Hz
Caleo_EU080060KR| 80 W/m2| 600| 230 V| 50 Hz
Caleo_EU080080KR| 80 W/m2| 800| 230 V| 50 Hz
Caleo_EU080100KR| 80 W/m2| 1000| 230 V| 50 Hz
Caleo_EU130030KR| 130 W/m2| 300| 230 V| 50 Hz
Caleo_EU130040KR| 130 W/m2| 400| 230 V| 50 Hz
Caleo_EU130050KR| 130 W/m2| 500| 230 V| 50 Hz
Caleo_EU130060KR| 130 W/m2| 600| 230 V| 50 Hz
Caleo_EU130080KR| 130 W/m2| 800| 230 V| 50 Hz
Caleo_EU130100KR| 130 W/m2| 1000| 230 V| 50 Hz
Caleo_EU160030KR| 160 W/m2| 300| 230 V| 50 Hz
Caleo_EU160040KR| 160 W/m2| 400| 230 V| 50 Hz
Caleo_EU160050KR| 160 W/m2| 500| 230 V| 50 Hz
Caleo_EU160060KR| 160 W/m2| 600| 230 V| 50 Hz
Caleo_EU160080KR| 160 W/m2| 800| 230 V| 50 Hz
Caleo_EU160100KR| 160 W/m2| 1000| 230 V| 50 Hz
CHOOSING SYSTEM TYPE
CALEO heating systems are installed in compliance with the users’ demands and
match the technical parameters of each building. Certain finishing layers
define the system type.
The following system types are used as follows:
CALEO REG
Film heater for laminated floors
- Existing leveled base (as primary heating must be on an interim slab or insulated base slab)
- XPS foam boards of4-6mm fixed with power tape on the whole surface
- CALEO film heater fixed with power tape
- Connecting cables, electric insulation, temperature limiting sensor embedded in XPS foam board
- Moisture barrier of PE cover the whole surface with a thickness of 0,15-0,2mm
- Click-type laminated floor 4-14mm suitable for floor heating
CALEO DIRECT
Any ceiling with a minimum free height of 100mm
- Moisture barrier of PE covers the whole surface with a thickness of 0,15mm
- Non-flammable rock wool insulation of 2-5 cm, installed within plasterboard profiles
- CALEO film heater fixed with power tape parallel to plasterboard profiles
- Connecting cables, electric insulation, temperature limiting sensor on film heater’s surface fixed with power tape to structure
- Non-flammable plasterboard coating with surface treatment of plastic mesh for reinforcement
System 1 CALEO REG
extra-slim floor heating system
Please gather information about structures and inform the Client about the
required preparation works prior the installation. CALEO REG floor heating
system requires minimal thickness.
Installation is easy and fast.
BASE
- CALEO Reg can be installed as a primary heating system on the base slab with sufficient primary heat insulation below, or on interim slab with heated area below
- A primary isolation layer is not obligatory in the base slab if only comfort heating is installed
- Base must be dry, dust-free, leveled
FLOOR FINISH
- The coating can be laminated floor or strip parquet not exceeding the thickness of 14 mm.
Never use CALEO FILM HEATER under ceramic floor tiles or carpet.
FILM HEATER
- Depending on the required heating capacity the film types appropriate for the CALEO Reg system: 80W/m2 or 130W/m2 capacity with 50cm or 80 cm width.
- Always use the design program provided by BFV to determine the minimum heating surface and capacities.
- In the case of a primary heating system, the minimum film heater coverage must exceed 80%, ideal at 90%.
- Try to avoid using different capacities in one room. If possible, do not mix different film widths within the room.
Film heaters shall be laid at a maximum of 5 cm gap in case of Caleo REG floor
heating (it is recommended to keep a distance of 1-3 cm), 10-15 cm distance is
allowed from the walls.
The area occupied by fixed furniture shall be deducted from the heated area.
Any other furniture is recommended to stay on the legs. Final layout of the
film heaters shall be adjusted on-site to actual parameters if necessary.
System 2 CALEO DIRECT
ceiling heating system
CALEO
DIRECT system is recommended for buildings when the installation of floor
heating is not possible (lack of floor isolation or non-replaceable floor
covers) We also suggest equipping the rooms with CALEO DIRECT system when the
floor surface is small to transmit sufficient heating capacity (eg. bedroom).
Depending on capacity sizing the CALEO DIRECT system is perfect for primary as
well as for comfort heating.
CEILING STRUCTURE
- The wall- or ceiling structure must be dry and capable to bear the load of the suspended plasterboard system
- The system requires at least 100mm of free internal height. Please also check openings when defining available free height of the rooms
PLASTERBOARD
- Profiles of the suspended ceiling shall be installed parallel with a distance of 40 cm. For isolation use nonflammable rock wool between the profiles with a thickness of min. 20mm, ideal from 50mm
or above
FILM HEATER
-
We recommend only elements of 160W/m2 capacity film heater at 30 cm width for CALEO DIRECT system
-
Always use the design program provided by BFV to determine the minimum heating surface and capacities
-
Minimal film heater coverage must exceed shall always match the actually calculated capacities.
Please pay attention to even distribution of film heater lines in the ceiling structure -
In case of comfort heating concentrate the capacities to the comfort zones of stay
FILM HEATER
-
We recommend only elements of 160W/m2 capacity film heater at 30 cm width for CALEO DIRECT system
-
Always use the design program provided by BFV to determine the minimum heating surface and capacities
-
Minimal film heater coverage must exceed shall always match the actually calculated capacities.
Please pay attention to even distribution of film heater lines in the ceiling structure -
In the case of comfort, heating concentrate the capacities to the comfort zones of stay
In the case of comfort heating, Caleo DIRECT system can be installed
irrespective of the furniture positions, however, it is recommended to place
the heating elements above the comfort zone (e.g. bed, table, or couch) and
concentrate on the areas with higher heat loss (main walls, external
openings). Please pay attention to the positions of lighting during
installation.
The final layout of the film heaters shall be adjusted on-site to actual
parameters if necessary.
Suggested order of layers
CALEO REG
thin-layer floor heating system
Suggested order of layers CALEO REG
thin-layer floor heating system| Suggested order of layers CALEO DIRECT
ceiling and wall heating system
---|---
Floor heating under laminate and other floating floors
- Floated floor (laminate floor)
- PE foil
- CALEO heating film
- XPS insulation board
- Insulated concrete base
Ceiling or wall heating in plasterboard
- Insulated ceiling structure
- PE foil
- ROCKWOOL insulation
- CALEO heating film
- Suspended ceiling (plasterboard)
SAFETY INSTRUCTIONS
FOLLOW THE STEPS FOR THE SAFE INSTALLATION
Preparation Before Installation
A. Confirm the electric capacity of the installation location.
It should be enough to accommodate the total output of the film.
B. Be sure the subfloor is clean, rigid, flat, level, and free of cracks
and objects that can damage the film.
C. Determine how many thermostats should be needed and the location of
each thermostat.
D. Drill or cut a hole for the electrical junction box.
E. Make groove for the path of wires (power & sensor)
IMPORTANT SAFETY NOTICE
WARNING: Shock and fire hazard!
-
If the CALEO System is damaged or not installed properly, fire or shock hazards could occur resulting in serious personal injury and damage to property.
You must carefully follow the warnings and instructions contained in this manual. -
Use controllers only designed for electric floor heating systems.
-
It is important that this equipment is installed only by qualified electricians who are familiar with the proper sizing, installation, construction and operation of floor warming systems and the hazards involved. The installation must comply with all national and local electrical codes. If you are unfamiliar with these requirements, contact an electrician.
-
The CALEO System is designed for underfloor and ceiling heating purposes only. Be sure that the floor is not penetrated by nails, screws, or similar devices that can cause damage on first installation or during subsequent floor repairs in the future.
-
If the CALEO System is damaged, it must be replaced. Do not attempt to splice or repair any part of the system.
-
CALEO is a heating element, not a full-ready plug-in the heating device.
-
The installer must decide whether he uses the “earthing” solution or not.
-
Please follow an official local electrical protocol of “earthing” to use CALEO system.
-
The appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction.
-
Children are being supervised not to play with appliances.
Safety Guidelines
The safety and reliability of any floor heating system depend on proper
design, installation, and testing. Incorrect installation or mishandling of
the product can cause damage to the heating cable, system components, and
property, and can create a risk of fire or shock. The guidelines and
instructions contained in this guide are important. Follow them carefully to
minimize these risks and to ensure that the CALEO system performs reliably.
Pay special attention to the following notices:
- Instructions marked Important
- Safety warnings identified as WARNING
Remember to measure resistance
The resistance should be measured between the two conductors. Compare this
resistance reading to the resistance specified. The value should be within
-10% to +10%. If you get a different reading, contact to the distributor.
Also, measure the resistance between the wiring cables. Both should read
infinity. If you get a different reading, contact to the distributor.
Important: measure the resistance four times during the installation
Remember to always measure, verify and record the actual resistance throughout
the installation process.
INSTALLATION
FOLLOW THE STEPS FOR THE SAFE INSTALLATION
You will require the following items to install and test the floor heating system:
| • Scissors | • Screwdriver |
|---|---|
| •Utility knife | • Multimeter |
| • Wire strippers | • CALEO connectors |
| • Tape measure | • CALEO Bit. Tape |
Plan layout
Make a sketch layout or a floor plan of the room; include all permanent
furnishings such as toilets, bathtubs, appliances, cabinetry, etc. Indicate
all dimensions required to determine the available floor area and the position
of the thermostat.
STEP 1
Place the XPS insulation board on 100% of the total area. Make sure the
surface is even, dry and properly fixed with tape.
STEP 2
Cut to size and place the heating film according to the pre-designed layout.
Make sure that heating film will not be installed under fixed furniture. You
can see the cutting line only on the backside of the film. Never cut or damage
the carbon part. Never leave or place any tools on the film heater.
STEP 3
Wiring. Do the wiring according to the scheme below. Always check the
connector is fixed properly and that the bituminous tape is flattened.
Never forget to cut a tunnel in the insulation board to hide the connection and cables.
Install floor sensor
If using a floor temperature sensing thermostat, install the sensor now,
preferably in a conduit tube, or directly to the subfloor. It is recommended
that the sensor be installed in a conduit tube. This will allow the sensor to
be easily replaced in the unlikely event of failure. The sensor and/or tube
need to be installed between the thermostat wall box and the sensor position.
The conduit tube must be partially countersunk into the subfloor.
STEP 4
Insulation resistance test
This test ensures that the insulating materials of the film heater are not
damaged.
-
Make sure the meter reads “open” or “infinity”.
If you get a different reading, contact to the distributor. -
Record these readings on the warranty card.
Heating film resistance test
This test measures the resistance of the CALEO Heating Film and is used to
determine circuit integrity.
- Set your multi meter to the 200 or 2000 ohm range
- Connect the multi-meter leads cold lead wires.
- Compare this resistance reading to the resistance specified in the Product Selection. The value should be within -10% to +10%. If you get a different reading, contact to the distributor.
- Record these readings on the warranty card.
STEP 5
Water barrier foil
Make sure all cables and connection points are fit in the tunnel and under the
insulation material level. Then place the water barrier PE foil on the total
area of the room. Then the heating system is ready for handover.
STEP
6
Thermostat settings
Make all necessary parameters and program settings according to the user
manual of the thermostat.
Floor limit temp. Never exceed the 29-31°C
In-ceiling heating mode the limit temp. Should be between 40-50°C
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>