For the qualified installer

ROTEX tacker systemFor ROTEX floor heating and cooling systemsInstallation instructions

Applicable to

ROTEX folding plate 30-3

ROTEX rollable track 30-3

with ROTEX heating pipes: Monopex 14

Monopex 17

GBEdition 04/2011

List of contents

2 FA ROTEX TACSYS - 04/2011

1 Warranty, safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2.1 Refer to the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2.2 Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2.4 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1 Assembly prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 Laying the system insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 Laying floor heating pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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1 Warranty, safety1.1 Warranty conditions

The legal guarantee conditions fundamentally apply. Our warranty conditions beyond that can be found online on your sales presentative's webpage.

1.2 Safety

1.2.1 Refer to the manual

This instruction manual is directed at persons who are authorised and who have successfully completed an enabling technical or training course in a skilled trade.

All the activities required for assembly are described in this manual. For detailed information on other components required for the assembly please refer to the respective documents included in the delivery.

Please read these instructions carefully before starting the assembly.

Relevant documents ROTEX RMX heating circuit manifold; the relevant installation instructions. ROTEX Monopex; the relevant installation instructions.

The manuals are contained in the scope of delivery of the respective components.

1.2.2 Warning signs and explanation of symbols

Meaning of the warningsWarnings in this manual are classified according into their severity and probability of occurrence.

DANGER!

Draws attention to imminent danger.

Disregarding this warning can lead to serious injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning can result in serious injury or death.

CAUTION!

Indicates a situation which may cause possible damage.

Disregarding this warning may cause damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

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Special warning signs

Some types of danger are represented by special symbols:

Order numberNotes related to order numbers are identified by the shopping cart symbol .

Handling instructions Handling instructions are shown as a points list.

1. Actions of which the sequential order must be maintained are numbered.

Results of actions are identified with an arrow.

1.2.3 Avoid danger

The ROTEX tacker system is built according to the state of the art and recognised norms on technology. However, improper use may result in serious physical injuries or death, as well as property damage.To prevent hazards only assemble the ROTEX tacker system: as intended and in perfect condition, with an awareness of safety and the hazards involved.

This assumes knowledge and use of the contents of this manual, of the relevant accident prevention regulations as well as the recognised safety-related and occupational health rules.

1.2.4 Instructions for operating safety

Hydraulics Create a heating system according to the safety requirements of EN 12828.

The floor heating must meet the following requirements: in the EN 1264: Floor heating systems and components in the EN 13813: Screed mortar, screed dimensions and characteristics and requirements

OperationROTEX do not operate floor heating until completion of all installation and wiring work.

Documentation The technical documentation included in the scope of supply is a constituent part of the system. It must be stored in such a

way that it can be consulted at any time by the operator or the technicians.

Danger of burning or scalding

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2 Installation2.1 Assembly prerequisites

System planning documents (e.g. the system structure, the heating pipe, the arrangement of the heating circuits) must be co-ordinated and, prior to the start of the assembly, submitted to the engineer.

The base and the heating system must correspond to the standards featured in chapter 1.2 "Safety". The base is clean, firm and dry.

Adopt a suitable sealing measure for installations against soil. In the case of partitions, if required adapt sealing measure against residual moisture from the concrete ceiling.

The base has been inspected for flatness tolerances and, if required, a level compensation has been performed. The height position of the complete floor heating system has been checked and it is ensured that the planned installation can

be executed in accordance with the height. The assembly material is available in its entirety and undamaged on the installation site.

2.2 Laying the system insulation

1. If required, prepare additional insulation.

WARNING!

In the case of sealing measures prepared with PVC or seals containing solvent, a separating layer (e.g. PE film) must always be used to prevent softening agent migration. This could lead to severe damage of polystyrene insulating materials.

CAUTION!

Polystyrene insulation materials can be easily damaged or destroyed as the result of external effects.

Never stress the insulation with pointed objects (pointed shoe heels, ladders or other sharp-edged objects). If required, a large and firm protective base should be used.

Never fold the insulation or bend excessively.

If lines from other installations, e.g. electric lines etc. are present a compensatory insulating layer must be provided to ensure that a closed surface can be obtained with the system plates. This is applicable, in particular, when using calcium sulphate screed (floating screed).

2. ROTEX place edge insulating strips (RDS, 17 11 01) on all vertical components (e.g. walls, stairs, steps, columns etc.).

Fig. 2-1 Laying edge insulating strips

Fix the edge insulating strip to the wall with double-sided sticky tape or with a tacker.

To prevent sound bridges, when using a tacker the edge insulating strip may only be fixed above the planned screed height.

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3. ROTEX lay out system insulation for the tacker system (folding plates 30-3 or rollable track 30-3). It can be cut to size using a commercially available blade.

Fig. 2-2 Laying out ROTEX folding plate 30-3 Fig. 2-3 Laying out ROTEX rollable track 30-3

4. Cover overlapping grid foil on the impact edges of both system insulations together with sticky tape.

1.1 System insulation1.2 System insulation grid foil2 Sticky tape

Fig. 2-4 Covering the impact edges of the system insulation together

5. Spread the welded PE film on the edge insulation strips evenly on the system insulation (avoid sound heat bridges).

1.1 System insulation1.2 System insulation grid foil3.1 Edge insulation strip3.2 PE film on the edge insulation

strip

Fig. 2-5 Spreading the PE film of the edge insulation strips evenly on the system insulation

6. In the case of floating screed: Fix spread PE film with sticky tape on to the system insulation to prevent slipping.

1.1 System insulation1.2 System insulation grid foil2 Sticky tape3.1 Edge insulation strip3.2 PE film on the edge insulation

strip

Fig. 2-6 Fixing PE film with sticky tape on to the system insulation to prevent slipping.

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2.3 Laying floor heating pipes

Roll out floor heating pipes twist-free according to the planned layout as well as the planned laying distance on the system insulation and fix with tacker needles. ROTEX tacker needles (TN40, 17 11 35) for heating pipes 20 mm. ROTEX system tacker (STAC, 17 11 34)

Connect heating pipes to the heating circuit manifold (see instruction manual for the heating circuit manifold used).

Fill heating system and check the tightness. Determine the moisture measuring position with screed layer. Incorporate screed. Dry heat, create protocol and countersign. Adjust the system and handover to the customer.

Prior to laying the heating pipes, the necessary expansion joints must be discussed with the project planner and the screed layer.

Heating circuits must also be divided up in such a way that the expansion joints are not passed through. Connection lines which pass through the joint must be fitted with a protective pipe measuring approx. 30 cm to protect the heating pipe from shear stress.

Fig. 2-7 Fixing floor heating pipes with ROTEX system tacker on system insulation.

Fig. 2-8 Maximum distance between the tacker needles 500 mm.

Fig. 2-9 Place a tacker needle before and after each elbow pipe. Fig. 2-10 Do not undershoot the minimum bending radius (R).

WARNING!

Heating pipes in the vicinity of the heating circuit manifold additional heat insulation to avoid overheating in this area (e.g. through a corrugated pipe projecting out of the plastic).

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