Klima 500 User manual

INSTALLATION INSTRUCTIONS (NEW BUILD ONLY)
KKLLIIMMAA
ELECTRIC UNDERFLOOR HEATING CABLE

Dear Client,
Congratulations on the purchase of this KLIMA product. The KLIMA CABLE is manufactured
from high quality, durable materials. To guarantee that your product functions optimally
there are a few points of attention which are described in the Installation Instructions. We
can only offer you the full guarantee if the KLIMA CABLE is correctly installed in accor-
dance with the Installation Instructions. Carefully read the instructions prior to installation,
do not forget the red centre page when doing so, and ensure that you have the correct
tools and materials. The electrical installation must be carried out by a qualified electri-
cian in accordance with IEE Regulations.
If you have any questions or require more information then you can:
contact the Support Line Monday to Friday from 9 am to 5 pm:
0870 - 411 1115
or visit our website for more information and other products at:
WWW.KLIMA.CO.UK
© 01-2007 Klima Underfloor Heating Ltd, P.O. Box 2009, Aberfeldy, Perthshire, PH15 2WB
KLIMA CABLE INSTALLATION INSTRUCTIONS
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1. CHECK:
Check the contents of the box before starting. A complete set consists of:
- A heating cable with connecting wire
- Inspection card
- A digital clock or Manual thermostat including floor sensor (Order as separate item)
- A flexible sensor pipe
- Spacer Strip pack
- Expansion Foam
- Installation Manual
- Installation video download available on www.klima.co.uk
2. TECHNICAL DETAILS:
TYPE WATTAGE AMPÉRE OHM METER LENGTH
Set 500 500Watt 2,1 109 30m
Set 1000 1000Watt 4,3 53 59m
Set 1700 1700Watt 7,4 31 100m
Heating cable : XLPE insulated solid resistance cable,
Tinned copper earthing conductor,
Aluminum screen,
PVC outer jacket
Type cable : Two conductor / series resistance
Diameter : 7,5mm
Power : 230Volt
Wattage pro mtr/l : 17 Watt/mtr. / 230Volt
Elements values : 500 to 1700 Watt
Bending radius : min. 37,5 mm
Max.cable temperature : 65°C outer jacket temperature
connection wire : 2.25 mtr. length
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3. POINTS OF ATTENTION:
The cable is insulated and watertight and can be installed on Foil finished insulation
(Kingspan or Celotex) or existing concrete bases. The construction of the cable also allows
installation in wet spaces. The heating cable may never be installed under fixed objects
like wall units, kitchen units, baths, or showers and must be able to give off its warmth
unimpeded.
The power supply must be disconnected during installation. All installations must be wired
through a suitably rated MCB or RCCD when applicable. All installations in wet areas
must be wired through a dedicated RCCD in line with the thermostat. All connections must
be made by an approved Electrician in accordance with current IEE regulations.
The electrical heating cable is patented worldwide and fully conforms to the European
IEC 800 standards.
The cables capacity is 17W per meter at 230V. The invisible transition of the resistance
cable (heating section of the cable) to the power cable (cold connection part of the
cable) is indicated by the word "SPLICE" between two arrows. The 2 meter power cable
marked with stars: ******, may be extended.
THE HEATING CABLE CANNOT BE SHORTENED!!!! THE END SEAL CANNOT BE BROKEN!
This Klima Cable is a twin conductor (built in return cable) and has an extra aluminium
earth cladding to neutralise magnetic fields.
If multiple cables are installed in a space, they must be wired in parallel and a suitably
rated junction box may be incorporated so that only one power cable runs to the thermo-
stat. Maximum capacity of the thermostat is 16 Amperes. If fitting more than one cable
set and the combined area length exceeds 3400 watts, a suitably rated Contactor will
have to be fitted. The thermostat may only be installed by a qualified electrician.
The Klima Cable can be used under various floor finishes - Tile, Marble, Slate, Wood,
Laminate, Vinyl and Carpet. (Tog rate of carpet and underlay should not exceed 2.5).
If using underneath a wooden floor or carpet please contact your flooring supplier.
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4. GUARANTEE:
The electro technical part of the floor heating is guaranteed for 10 years. The thermostat
is guaranteed for 2 years. The guarantee does not apply to damage caused by external
factors and/or incorrect installation.
5. NECESSARY MATERIALS:
- Standard junction box (min 35mm deep, preferably 50mm) for the thermostat.
- Mounting material: Tie wraps, Spacerstrips or smooth Weld Mesh.
- Electrical conduit for the connecting cable for the thermostat.
- A multimeter to test the mat after each installation activity.
6. PREPARATIONS:
- Check that the cable length/wattage is correct for the area of free floor surface that
must be heated.
- Check the available electrical connection and mains voltage in the space for installation.
- Test the cable with a multimeter and check if the resistance (Ohms) coincide with the test
data in Section 2. Measure both between the resistance wires themselves and between
the resistance wire and the earth cladding, whereby the latter should give a reading of
0 and not swing.
- 1 or 2 grooves must be cut/ground in the wall for electrical conduits, 1 for the power
cable and 1 for the floor sensor. Do not run the power cable and sensor cable through
the same pipe.
TAKE CARE: DO NOT PLACE THE SENSOR IN THE VICINITY OF A (HIDDEN) RADIATOR
OR WATER PIPE!
- Ensure that the base floor is clean and level.
- Always apply insulation to the base floor if possible. Uninsulated floors will have
downward heatloss.
- Place expansion strips around the perimeter of the area (for coping with the contraction
and expansion of the floor).
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7. CALCULATIONS FOR HEAT REQUIREMENTS:
150 + watts/m² for prime heating of normal rooms cable spacing 100 mm
100/125 Watt sq. m for comfort heating of normal rooms cable spacing 125/150 mm
Example: for a Kitchen of 20 sq. m floor surface multiply the total floor surface with the
above mentioned capacities (20 x 150 Watt = 3000 Watt) Choose 2 x 1700 watt.
Cable can be sized (or checked) by measuring the linear length i.e. Heat required 150
watts/m².
Room size 4mx2.5m = 10m² Cable spacing = 100mm Therefore 4mx25 = 100 linear mts.
Use 1700 Watt set (100 linear mts).
If there is any excess cable left after installation, you can space a few runs at 50mm at
the window & door areas of the room to lose it in the floor.
Please contact the KLIMA Technical Department (0870 411 1115) if you require assis-
tance on the spacing of the cable.
NEVER SHORTERN THE KLIMA CABLE!
8. RESISTANCE READINGS:
Please make a note of your resistance readings in the table below. This forms your guar-
antee. Readings to be taken with an ordinary Multimeter. Please also make note of the
resistance readings on your inspection card.
* Should always read open circuit. If not: STOP immediately and call the technical helpline.
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Cable type:................W Initial Cable Laid Completion
Live & Neutral ΩΩΩΩΩΩ
Live & Earth*ΩΩΩΩΩΩ
Neutral &Earth*ΩΩΩΩΩΩ

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PREPARATIONS:
INSTALLING SENSOR:
RESISTANCE READINGS:

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9. FITTING THE CABLE TO THE FLOOR:
Feed the cable end (marked with *******) through the electrical pipe to the back box for
the thermostat. The word "splice" must stay visible. Splice must be covered by screed.
Fix the spacer strips at 500 - 600 mm centres with masonary or Hilti nails. Attach the
cable in a zigzag fashion with a distance between the cable as required.
If reinforcing is used (*Smooth Weld mesh at 100mm square) plastic tie wraps can be
used for attaching the cable directly to the reinforcing.
Extend the 2nd electrical pipe to about 50 cm from the wall and have it end in the mid-
dle of a cable loop. Pull the sensor cable to the back box and ensure that the sensor is in
the conduit. Ensure the cap is placed on the end of the conduit so that replacing the sen-
sor is always possible.
Please contact the KLIMA Technical Department (0870 411 1115) if you require assis-
tance on the spacing of the cable.
*Refer to centre pages.
10. APPLYING THE MORTAR:
10 A: APPLIED DIRECTLY TO A CONCRETE SUBFLOOR:
1. Lay the spacer strips at 500 -600mm centres. Attach the cable at the desired/
specified spacing.
2. Ensure a good bond by brushing the subfloor with cement powder or PVC glue.
3. Then apply a layer of sand/cement screed (5/6:1) of 3.5 to 5.0 cm. Allow it to cure
before the tiles can be laid or other types of floor coverings applied.
4. This method of application is also suitable for applying pourable liquid screeds in
thicknesses of between 3 and at most 6 cm.
5. Protect the cables when bringing in the cement or grout by using duckboards. Never
use wheelbarrows with unprotected footrests.
NB: For large spaces it is necessary to create or observe expansion joints in multiples of
approx. 40/50 m2. The cables may not cross the expansion joints to avoid damaging
the cables.
6. Remember to take the resistance readings throughout this installation process.

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SPLICE!
FITTING THE CABLE
APPLYING THE MORTAR:

10 B: APPLIED DIRECTLY ON TOP OF INSULATION:
When laying the KLIMA CABLE onto the insulation the KLIMA CABLE must be laid and
secured onto a steel mesh. Do not install the cable directly onto the insulation. The cable
is laid on to a smooth reinforcing mesh (approximately 100mm square), and secured with
tie wraps. When using insulation, the top surface of the insulation must be aluminium cov-
ered and coated appropriately to resist reaction with screed. Kingspan and Celotex man-
ufacture insulation boards for the sole purpose of underfloor heating. The cable must not
come into contact with the insulation. Contact the insulation manufacturer for compatibility
with cable floor heating systems and fitting instructions.
The minimum depth of screed is 75mm. It is very important that the bedding is applied
free of air bubbles. Air bubbles form insulating, non-conductive areas where the cable
cannot release its heat and a danger of overheating arises which can cause damage to
the cable. To avoid this first of all wetter screed must initially be used to enclose the
cable in the screed. Following this drier cement can be used for levelling the final bed-
ding. In this case a pourable liquid screed is also a good option. Protect the cables when
bringing in the cement or grout by using duckboards. Never use wheelbarrows with unpro-
tected footrests. Remember to take the resistance readings throughout this installation
process and mark opposite.
10 C: ON DOVETAILED SHEETING:
Always allow for expansion. Dovetailed subfloors offer very poor insulation. It is recom-
mended the dovetailed sheeting is insulated from below. Then fill in the grooves with mor-
tar before installing the cables. Then install as indicated in Chapter 10A. In the latter case
pourable liquid screed method can also be applied. Protect the cables when bringing in
the cement or grout by using duckboards. Never use wheelbarrows with unprotected
footrests.
11. USING THE SYSTEM FOR THE FIRST TIME:
Depending on the drying time specified for the cement or grout, however not sooner than
30 days after installation due to the natural expulsion of moisture from the floor. Turning
on the system sooner can damage the floor.
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SPLICE!
SPLICE!
FITTING DIRECTLY ON TOP OF INSULATION:
FITTING ON DOVETAILED SHEETING:

CONNECTING THE FHT/S-CONTROL: During installation/de-installation of the thermostat the electricity should always be turned off at the mains. Installation must be carried out by a qualified electrician in accordance with the IEE Regulations. The FHT-Control thermostat is equipped with an intelligent guide function that leads the user through the programme and is extremely user friendly. Still carefully read this manual nevertheless and keep it with your other guarantees. INSTRUCTIONS FOR THE ELECTRICIAN: Check that the electricity is turned off. Remove the display housing by inserting a blunt, suitable instrument, e.g. a coin or point of a ballpoint carefully into the square hole at the top of the thermostat and exerting a light pressure. Both the display housing and the cover plate can then be removed. WIRING DIAGRAM: Installation is done as follows: - 1, 4 and 5 (earth) are used for the connection wires from the heating cable. - 2 (Neutral), 3 (Live) and 6 (Earth) are for the power supply. - 7 and 8 (earth) are for connecting the sensor. INSTALLATION: Position the thermostat and mount and secure it in the back box with two screws. Replace the cover plate and position the display housing back in place and softly press it into position. When the power is turned on the first question will be dis- played on the start up menu. Follow the start up menu carefully.

Please note that where there is no matting or cable installed the floor will not be heated! If the mat is too long the cable can be cut loose from the fibre netting and installed in loose strips. Loose cables must be looped at least 4 cm from each other. They may not touch or cross each other. The sensor must be installed in the middle of a cable loop for optimal temperature registration. Ensure that the sensor is installed well clear (min. 50 cm) of (hidden) radiator and water pipes, drains and electrical wiring. The Mat or Cable may never be installed under fixed objects like wall units, kitchen units, baths, or showers and must be able to give off its warmth unimpeded.

PLEASE READ CAREFULLY:
IMPORTANT POINTS OF ATTENTION FROM THE GENERAL INSTALLATION INSTRUCTIONS
ALL FLOORS SHOULD BE INSULATED BEFORE UNDERFLOOR HEATING INSTALLATION.
INSTALLING FLOOR HEATING: KLIMA CABLE: The connecting cable CANNOT be shortened. The part of the cable with the word **SPLICE*** must be installed in the floor screed. Shortening the connecting cable for the KLIMA MAT: The connecting cable may be shortened AT MOST by 3 meters (no less than 2 meters). All cables that are attached to the mat must be installed in the floor. Extending connecting cables: The connecting cables can be extended as required. Take however the capacity (Amps) of the floor heating into account and adjust the capacity of the extension cables accordingly. FLOOR SENSOR INSTALLATION: Ensure that the sensor is installed well clear (min. 50 cm) of central heating pipes, water pipes, drains and electrical wiring. Install the sensor as closely as possible in the middle of 2 loops. Ensure that the heating cables do not make direct contact with the conduit in which the floor sensor is mounted. The end of the sensor pipe must be closed. Check that the sensor cable is free to move to the end of the pipe. Extending the floor sensor: The floor sensor may be extended as required up to a maximum of 10 meters. Use a signal

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cable for extending the sensor. Ensure that the sensor can always be replaced in case it fails. The simplest way of doing so is installing a hidden junction box in which the signal cable is connected to the sensor.
INSTALLING KLIMA CABLE ON WELD MESH: If using a porous floor finish such as limestone etc. on top of the screed, we recommend that the weld mesh is galvanised otherwise the rust off the mesh can rise to the top of your finished floor surface during time. USING THE FLOOR HEATING FOR THE FIRST TIME: Allow the floor sufficient drying time before you turn on the floor heating. For tiled floors a drying time of 3/4 weeks after installation should generally be observed. Consult the supplier/manufacturer regarding the applicable drying time for the product. For sand/cement screed floors a drying time of 1 week per applied cm with a minimum of 4-5 weeks is generally observed. onsult the supplier/manufacturer regarding the applicable drying time for your situation. ADJUSTING THE THERMOSTAT: Timer function: If you have a thermostat with a timer function and want to use it to set the floor drying time make sure you set a low comfort temperature. (15°C for example). When the thermostat automatically goes on (after the required dry- ing time) then the comfort temperature may be slowly raised (1°C per day) until the desired comfort temperature is reached. Other thermostat / settings: If you have a different thermostat or if you do not want to use the timer function ensure that you then set the comfort temperature low (15°C for example). After taking the required drying time into account you can then manually raise the floor temperature with approx. 1°C per day until the desired comfort temperature is reached.