NEXGEN PSU 2400w Installation Manual

Far infra-red heating system

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INSTALLATION MANUAL

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Page 1 INSTALLATION MANUAL...
Page 2 NexGen Far Infra-Red Heating System Contents Pages 1-14 – NexGen Ceiling Paper System • Pages 15-18 – NexGen Foam Backed System • Pages 19-23 – Power Supply Installation Manual • Pages 24-27 – Commissioning & Guarantee • • Pages 28-34 – Power Supply Data Sheets...
Page 3: Table Of Contents
NexGen Ceiling Paper System Contents Page 1 – Stay safe when installing • Page 2 – About the system • Page 3 – What you need • Page 4 – Before Installing / Ceiling Preparation • Page 5 – Prepare for the heating system •...
Page 4: Stay Safe When Installing
• NEVER CUT OR DRILL INTO THE COPPER: any cuts in the heating mats must be circular and leave at least a 100mm/10cm gap from the copper element. • Keep all NexGen parts in original packaging until use, to prevent them becoming damaged. • Shaking or dropping the equipment can damage internal parts.
Page 5: About The System
Controlling the heat is simple, users set the temperature for each room via our NexGen App or via traditional in-room thermostats. NexGen Supplied Materials: Primary Adhesive (Wallrock Power Adhesive) –...
Page 6: What You Need
WHAT YOU NEED: TOOLS & MATERIALS Plastic Edge Caulker - do not use metal edge tools as this can damage the product • Roller (long pile) • Roller extension pole • Roller Tray or scuttle • Paint Brush • Trimming Knife/Scissors •...
Page 7 • dampness, or grease should be investigated and rectified. All surfaces must be sealed with a minimum of two coats of the NexGen supplied primer. This • helps the adhesive to bond and prevents the subsurface from drawing moisture from the adhesive before it can properly cure.
Page 8 Stage 2: Preparation for the Heating System • A NexGen system guide layout has been provided showing the intended position of the heating mats and zones. Please familiarise with this before proceeding. • Heating mats are supplied in various lengths with electrical crimped contacts pre-fitted at one end. If the length of the product needs to be reduced in order to fit the size of the room, the paper can be cut with a sharp pair of scissors or a trimming knife.
Page 9: Wiring Route
Wiring Routes There are two methods of installing and concealing the wires: Surface-Mounted Wires can be concealed in several ways, either surface mounted, clipped to the wall/ceiling to prevent premature collapse, concealed within trunking or behind coving. Please consider the capacities of trunking and grouping factors before installing.
Page 10: Installation Process
1. Referring to the NexGen layout, mark out the position of each heating mat, with the aim of achieving an even distribution across the ceiling. Take care to ensure all connections line up along one edge of the room in advance of any trunking or coving installation.
Page 11 8. Larger gaps can be infilled with supplied NexGen blanking paper using same installation method just as the heating panels, as per steps 1 to 6 above. 9. Once finished take a step back and carefully check the installation from different angles to ensure all air pockets have been removed.
Page 12: Electrical Wiring & Power Supplies
ELECTRICAL WIRING & POWER SUPPLIES Consult NexGen Power Supply Manuals for guidance. After carefully planning the wiring routes from the power supply unit (PSU) location to each of the individual heating mats and chosen method of installation as outlined above, please continue with the steps below.
Page 13 3. Insert the open barrel type crimp into the crimping tool, and gently apply pressure to hold the crimp in place but not so much to compress crimp. Feed the cable into the opening, taking care that the copper is in the barrel area and the insulation is in the cable support area. Apply crimps to the end of each wire making sure there are no loose strands.
Page 14 PSU has a coloured cable and a black cable; these serve as the live/line and neutral for each heating element, although the mats themselves have no specific polarity. 7. All cabling in relation to the NexGen system must adhere to current Wiring Regulations.
Page 15: Finishing
FINISHING • Once the system has been fully tested and commissioned the final stage is to apply a chosen finish. We recommend using a lightweight easily sanded filler to fill any gaps in-between heating mats and to feather out any edges. Please take extra care when using metal edge filling tools around the installation.
Page 16 Technical Data Sheet; NXG Ceiling Paper System...
Page 17 Voltage range: 24-48 volts DC or AC RMS Operating voltage: 24 volts Efficiency: 100% Nominal thickness: 500um Operational Temperature Range: -20C to +60C Dimensions: Active width 560mm Total width 750mm Power output at 24 volts: 100-120 per metre Termination: Tinned copper crimp blade Maximum current: 15 Amps Composition: Class B Lining Paper encapsulating copper strips and a Carbon nanocomposite material.
Page 18 NexGen Foam Backed System Contents Page 15 – Overview & Ceiling Prep • Page 16 – Installation • Page 17 – Finishing • Page 18 – Technical Data Sheet •...
Page 19 NexGen Foam-backed Product NexGen also has a heating mat bonded to an insulated foam backing, below is the installation process for this product: Tools & materials Many of the tools and materials required for the paper product are needed for the foam, with the addition of fixing screws, a large roller, scrim tape and 3M 760 adhesive (Please refer to the MSDS prior to use).
Page 20 Installation: 1. 1. Referring to the NexGen layout, mark out the position of each heating mat, with the aim of achieving an even distribution across the ceiling. Take care to ensure all connections line up along one edge of the room in advance of any trunking or coving installation.
Page 21 Finishing • Once the system has been fully tested and commissioned the final stage is to apply a chosen finish. We recommend using a lightweight easily sanded filler to fill any gaps in-between heating mats and to feather out any edges. Please take extra care when using metal edge filling tools around the installation.
Page 22 Technical Data Sheet; NXG Foam Backed System...
Page 23 Voltage range: 24-48 volts DC or AC RMS Operating voltage: 24 volts Efficiency: 100% Nominal thickness: 10mm Operational Temperature Range: -25C to +60C Dimensions: Active width 560mm Total width 750mm Power output at 24 volts: 100-120 per metre Termination: Tinned copper crimp blade Maximum current: 15 Amps Composition: Class B Lining Paper encapsulating copper strips and a carbon nanocomposite material bonded to an...
Page 24 Power Supply Installation Manual Contents Page 19 – General Information • Page 20 – Safety Instructions • Page 21 – Mounting • Page 22 – Supply Requirements • Page 23 – Wiring the heating circuit •...
Page 25 General Information: Power supplies (PSU’s) will be available and supplied in the following product types; 2400B – 6x 400w Output 1600A – 5x 300w Output 1600B – 4x 400w Output 1200A – 4x 300w Output 1200B -3x 400w Output 800A – 2x 400w Output 800B –...
Page 26: Important Safety Information
• An air gap of 100 mm around all edges and 300mm from the face is mandatory. • The power switch must remain freely accessible. • Before drilling the mounting holes, check for concealed pipework or cables. • If the mains connection cable of the PSU is damaged please consult NexGen to arrange a replacement.
Page 27 Allow suitable airflow for ventilation. • The PSU and switch gear needs to be accessible. • The wall must be strong enough to safely support the weight of the device. Weight (kg) PSU 2400w PSU 1600w PSU 1200w 16.85 PSU 800w 10.6...
Page 28 Supply requirements We recommend that a dedicated circuit is provided for the NexGen system. The circuit is protected by an RCD paired with a Type D MCB or Type D RCBO to prevent the nuisance tripping caused by the potential high inrush current from the PSU’s. An earthed mains supply must...
Page 29 Wiring The Heating Circuits 24 v Only use the enclosed flexible heating circuit connecting cables with supplied connectors. If any fuse blows, it must be replaced with the same value fuse. Refer to the power supply data sheets for the correct-sized fuse for the relevant PSU.
Page 30 Commissioning & Guarantee Contents Page 24 – Commissioning & testing • Page 25 – Electrical Commissioning Document • Page 26 – Heating mat commissioning Document • Page 27 – Guarantee •...
Page 31 Should a higher value be found please check wiring connections and rectify. IMPORTANT - To activate the Guarantee a commissioning document is required to be completed and retuned to Nexgen. This can be found on the following page for both Electrical & Heating Mat Installation.
Page 34 In the event of a failure please contact NexGen. In the case of a defective heating mat supplied by NexGen Carbon Zero Ltd, NexGen Carbon Zero Ltd will replace the defective heating mat. Faults caused by incorrect installation or fitting procedure, misuse or damage caused by third parties, will not be covered under this guarantee.
Page 35 Power Supply Technical Data Sheets Contents Page 28 – 400w • Page 29 – 800w-A • Page 30 – 800w-B • Page 31 – 1200w-A • Page 32 – 1200w-B • Page 33 – 1600w-B • Page 34 – 2400w-B •...
Page 36 Power Supply Technical Data Sheets; 400w Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 1.6 Amps Inrush current: Limited to 20Amps Total output power: 400w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.0mm Flex Cable –...
Page 37 Power Supply Technical Data Sheets; 800-A Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 3.4 Amps Inrush current: Limited to 20Amps Total output power: 800w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.0mm Flex Cable –5 Amp fused connection unit required Output heating circuit voltage: 24 volts AC (SELV) Output protection: 20 Amp thermomechanical cut-out...
Page 38 Power Supply Technical Data Sheets; 800-B Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 3.4 Amps Inrush current: Limited to 20Amps Total output power: 800w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.0mm Flex Cable –...
Page 39 Power Supply Technical Data Sheets; 1200-A Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 5.6 Amps Inrush current: Limited to 20Amps Total output power: 1200w Individual output current Power per output: 300w Efficiency: 94% Protection class: IP20 Power connection: 1.0mm Flex Cable –...
Page 40 Power Supply Technical Data Sheets; 1200-B Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 5.6 Amps Inrush current: Limited to 20Amps Total output power: 1200w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.0mm Flex Cable - 10 Amp fused connection unit required Output heating circuit voltage: 24 volts AC (SELV) Output protection: 20 Amp thermomechanical cut-out...
Page 41 Power Supply Technical Data Sheets; 1600-B Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 7 Amps Inrush current: Limited to 20Amps Total output power: 1600w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.5mm Flex Cable –...
Page 42 Power Supply Technical Data Sheets; 2400-B Input Voltage: 230 volts +10/-6%, 50 Hz. Input current, max continuous: 11.3 Amps Inrush current: Limited to 20Amps Total output power: 2400w Individual output current Power per output: 400w Efficiency: 94% Protection class: IP20 Power connection: 1.5mm Flex Cable –...

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