Warm Your Floor WarmWire Installation Manual
Contents
1. CableStrap Bath Tub 27 of 32 2015 Watts Water Technologies Master Bathroom normal heat loss framed floor construction Two zones 120 volts Two Cables HINTON Y Zone 1b Bath Tub O Shower Curb Cable End CableStra cable Ena i a Floor Sensor Toet Install cables at least 6 away from toilet rings Example of Cables only with W on the nameplate label where cable is installed in a shower area and enters over the curb Shower Details Shower Curb WarmWire Avoid sharp bends in cable Factory Splice See phase 3 for complete details and Cautions This application into a shower area must be verified by the local inspector or the authority having jurisdiction IOM WYF WW 1528 28 of 32 Troubleshooting Guide If not qualified to perform electrical installations it is strongly recommended that a qualified licensed electrician be hired to install the heating cables and related electrical components If problems with the system arise please consult the troubleshooting guide below A WARNING Any electrical troubleshooting work should be performed with the power removed from the circuit unless otherwise noted Problem Possible Cause Solution Cable resistance measurement is outside the range printed on the nameplate label An analog ohmmeter using a moving needle was used to take the reading Obtain a digital ohmmeter able to read 0 to 20 000 ohms an2. F 27 to 28 C Check with the flooring dealer or manufacturer and set the thermostat Floor Limit temperature appropriately IOM WYF WW 1528 18 of 32 Phase 6 Floor Coverings General Recommendations NOTICE Please note this installation manual is not a structural or a floor covering installation manual and is intended only for general guidance as it applies to the SunTouch WarmWire product It is recommended to consult with professional flooring installers to make sure proper materials are used and proper installation techniques are followed When installing tile or stone the Tile Council of North America TCNA guidelines or ANSI specifications should be followed as a minimum standard A latex modified thin set cement based mortar and grout is recommended instead of water based multi purpose materials when installing a radiant product Do not use solvent based adhesives or pre mix mortars because they are not as heat resistant and do not conduct heat well If wire is installed using an attachment method other than CableStraps please follow manufacturer s thin set cement based mortar and grout recommendations Select the proper size trowel for the installation of tile or stone We recommend a minimum 3 8 x 1 4 trowel This trowel works well for most ceramic tile A thicker thin set can be used if required Select the thin set thickness in accordance with the floor covering requirements Fo
3. 10 years remaining in the warranty period will receive 10 25ths of the manufacturer s published list price of the Product at the time of purchase In order to make a claim you must a Provide the Company with sufficient details relating to the nature of the defect the installation the history of operation and any repairs that may have been made b At the Company s discretion and at the owner s expense ship the Product to the Company or the Company s local representative or distributor c Provide proof that the Product was installed in accordance with the applicable Product Installation Manual and any special written design or installation guidelines by the Companies for this project d Provide proof that the Product was installed in accordance with the National Electrical Code NEC or the Canadian Electrical Code CEC and all applicable local building and electrical codes e Provide a retail sales receipt or proof of purchase The following are not covered by this Limited Warranty a Any incidental or consequential damage including inconvenience loss of time or loss of income b Any labor or materials required to repair or replace the Product or control not authorized in writing by the Company c Any labor or materials required to remove repair or replace flooring materials d Any freight or delivery costs related to the Product the control or any related flooring or electrical products The C
4. date entered on the packing slip for the order Return Policy The Companies items may be returned within one year from the date of purchase if they are not damaged or used There will be a 15 restock charge applied to items returned due to overstock or customer order error All returned items must be in new condition Products controls or other parts that have a quality defect will be replaced not credited at no charge to the customer If an item is shipped in error there will be no restocking charge All items returned for replacement credit or repair must have a Returned Goods Authorization RGA number or they will not be accepted Please call our order desk for an RGA number Products older than one year are excluded from these terms and conditions and may not be returned No returns will be accepted for the Custom TapeMat product Products that have been damaged or Products that have been cut may not be returned This includes Products that have had mortar or concrete materials applied to them These Products cannot be repaired and cannot be resold therefore we cannot accept them Effective APRIL 1 2006 This warranty applies to all Products purchased after this date 2015 Watts Water Technologies warmyour floor the radiant floor heating experts IOM WYF WW 1528 Warm Your Floor 23055 Alcalde Drive Laguna Hills CA 92653 Toll free 866 558 3369 Fax 866 558 2010 WarmYourFloor com 2015 Watts Wa
5. install WarmWire under carpet wood vinyl or other non masonry flooring without embedding it in thin set thick set or self leveling mortar NEVER install WarmWire in adhesives or glues intended for vinyl tile or other laminate flooring or in pre mix mortars It must be embedded in polymer modified cement based mortar NEVER cut the heating wire Doing so will cause dangerous overheating and will void the warranty The power lead may be cut shorter if necessary but never remove completely from the heating wire NEVER bang a trowel or other tool on the heating wire Be careful not to nick cut or pinch the wire causing it to be damaged NEVER use nails staples or similar to fasten the heating wire to the floor NEVER attempt to repair a damaged heating wire splice or power lead using unauthorized parts Use only factory authorized repair NEVER bang a trowel or other tool on the heating cable parts and methods NEVER splice one heating wire to another heating wire to make it longer Multiple WarmWire power leads must be connected in parallel in a junction box or to the thermostat NEVER install one wire on top of another or overlap the heating wire on itself This will cause dangerous overheating NEVER forget to install the floor sensor included with the thermostat NEVER install WarmWire in any walls or over walls or partitions that extend to the ceiling NEVER install wires under cabinets or other built ins having no fl
6. of several smaller areas 11 of 32 2015 Watts Water Technologies If using an attachment membrane like Schluter DITRA HEAT Membrane Prodeso Heat Membrane or RPM mat go to Step 3 8 Install CableStrap STEP 3 5 Measure the edge of the Heated Area where CableStrap will be installed STEP 3 6 Cut the CableStrap to length using metal shears STEP 3 7 Secure the strap to the floor Depending on the floor type different methods may be used Plywood cement board or similar Galvanized nails or screws may be used to secure the strap every 6 to 10 IOM WYF WW 1528 Concrete self level or similar Double sided tape if included with your cable hot glue or strong spray adhesive may be used if the floor is well cleaned and the strap is wiped free of any oils However it is highly recommended to also place screws at each end of the strap and every 4 to 5 feet to ensure it does not come loose If using a strong spray adhesive apply to both the back of the strap and the floor where it will be placed and carefully follow all soray manufacturer s instructions and cautions S WAS IX ws WF Spray adhesive Cut another piece of strap for the other end of the area and secure to the floor 12 of 32 A CAUTION Completely embed the Factory Splice and heating cable in the floor mortar Never bend the factory splice Ne
7. the control to be installed by an electrician IOM WYF WW 1528 2 of 32 Expected floor temperature Heating performance is never guaranteed The floor temperature attainable is dependent on how well the floor is insulated the temperature of the floor before start up and the overall thermal drain of the floor mass Insulation is required for best performance Refer to Phase 6 for important design considerations These are the three most common installations 1 Wood framing With the cable installed on a well insulated wood subfloor and thin set mortar and tile on top most floors can be heated up to 20 F warmer than they would otherwise be Insulated concrete slab With the cables installed on an insulated concrete slab and thin set mortar and tile on top most floors can be heated up to perhaps 15 F warmer than they would otherwise be Uninsulated concrete slab With the cables installed on an uninsulated concrete slab and thin set mortar and tile on top most floors can be heated up to perhaps 10 15 F warmer than they would otherwise be Please consult a designer or the factory if questions remain about the surface temperature that can be expected from the cables in any particular construction Please see Phase 7 Install Insulation on page 20 N Table of Contents Important Safety Information 3 Phase 6 Install the Floor Coverings 19 Phase 1 Preparations cc
8. to pull the wire 9 of 32 2015 Watts Water Technologies STEP 2 3 Bottom Plate Work Drill or chisel holes at the bottom plate as indicated One hole is for routing the power lead conduit and the other is for the thermostat sensor These holes should be directly below the electrical box es ka Power lead py L conduit Sensor wire Wire Clip If going in to an existing wall cut out dry wall and chisel out bottom plate to route wires to control Power lead Sensor wire STEP 2 4 Install Power Lead Conduit and Thermostat Sensor Power Lead Conduit The shielded power lead can be installed with or without electrical conduit recommended for added protection against nails or screws depending on code requirements Remove one of the knock outs in the electrical box to route the power lead If electrical conduit is not required by code install a wire collar to secure the power leads where they enter the box If conduit is required by code install 1 2 minimum conduit from the bottom plate up to the electrical box For multiple power leads multiple cables install 3 4 conduit SunStat Thermostat Sensor The SunStat sensor can be installed with or without electrical conduit depending on code requirements Conduit is recommended for added protection against nails or screws Do not place the sensor in the same conduit as the power leads to avoid possible interference Open a separate knock out
9. 424 ALWAYS use copper only as supply conductors to the thermostat Do not use aluminum ALWAYS seek help if a problem arises If ever in doubt about the correct installation proce dure to follow or if the product appears to be damaged the factory must be called before proceeding with the installation A WARNING Installation must be performed by qualified personnel in accordance with local codes and standards A licensed electrician is recommended Phase 1 Preparations Before installing WarmWire make sure to fully inspect the products and carefully plan the site Items Needed Materials e WarmWire system e CableStrap or a cable attachment membrane such as Schluter DITRA HEAT Membrane Prodeso Heat Membrane or RPM mat e SunStat Thermostat with floor sensor e SunStat Relay control if required e Control electrical box UL Listed extra deep see control instructions for size and type required e Junction electrical box if required see Step 2 2 e Wire nuts if a junction electric box is required see Step 2 2 must be UL Listed and proper size e Flexible or rigid conduit if required see Step 2 4 must be UL Listed and proper size e 12 guage or 14 guage electrical wiring cable UL Listed see Step 2 1 e Nail plate Tools e Digital multi meter for ohms testing must read up to 20 000 ohms 0 to measure sensor e Drill with 1 2 and 3 4 bits e Hammer and chisel e Hot glue gun and hot g
10. O 3 5 spacing g J o e NEVER space the cables less than 2 5 apart STEP 3 12 If there are additional areas to cover with cable cut the lengths of strap necessary attach them to the floor and begin weaving the cable into that area STEP 3 13 To secure long lengths of heating cable place additional short lengths of the strap at 3 4 ft intervals Spray the back of the strap with a high tack adhesive and slide the strap upside down under the cables Turn the strap over when it is positioned and adhere to the 2015 Watts Water Technologies floor Press the tabs down over the cables If a spray adhesive was not used carefully secure these short lengths of strap to the floor without damaging the cable Installing Cables on Attachment Membranes STEP 3 14 Weave the cable back and forth across the area at the desired spacing Maintain slight tension on the cable to ensure it does not pull loose If desired use hot glue at intervals to help ensure it stays secure NEVER space the cables less than approximately 2 5 apart RPM Mat 3 5 spacing Schluter DITRA HEAT or Prodeso Heat Install second cable STEP 3 15 If a second cable is to be installed in the area all power leads must come back to the control or to a junction box and then to the control NEVER run power leads across heating cables under baseboard areas or other potentially damaging areas Never join two ca
11. R MATS AND CABLES TO 15 WATTS PER SQUARE FOOT DEPENDING ON CABLE INSTALL SPACING AND UNDERFLOOR MATS TO 10 WATTS PER SQUARE FOOT AND AS SUCH USERS MAY OR MAY NOT BE SATISFIED WITH THE FLOOR WARMTH THAT IS PRODUCED THE COMPANIES DO WARRANT THAT ALL PRODUCTS WILL PRODUCE THE RATED OUTPUT LISTED ON THE PRODUCT NAMEPLATE WHEN OPERATED AT THE RATED VOLTAGE Some states do not allow the exclusion or limitation of incidental or consequential damages and some states do not allow limitations on how long implied warranties may last Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW ANY IMPLIED WARRANTIES THAT MAY NOT BE DISCLAIMED INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO TWENTY FIVE YEARS FROM THE DATE OF MANUFACTURE Terms and Conditions Shipping Discrepancies Incoming materials should be inven toried for completeness and for possible shipping damage Any visible damages or shortages must be noted prior to accepting the material Once the receiving personnel accept the material on their dock they have relieved the freight company of any responsibility Any discrepancy concerning type or quantity of material shipped must be brought to the attention of the Companies within 15 days of the shipping
12. bles in series Other Installations Because many different room shapes and floor obstructions may be encountered in any given installation additional layouts are provided below to assist in determining the best way to complete installations in odd shaped areas Corner shower or vanity using CableStrap STEP 3 16 For an angled area such as a corner shower lay CableStrap at an angle and adjust tab spacing to keep the wire spacing consistent STEP 3 17 Fill in the section with cable Make sure that the cables are spaced evenly and parallel to one another Door entryway using CableStrap STEP 3 18 For an entryway or other small area where warmth is required cut small sections of strap to fit the ends of that area AAA Approximate 2 5 spacing LAA AA AA A A A A A Approximate 3 5 spacing IOM WYF WW 1528 STEP 3 19 Fill in with cable adjusting spacing as necessary to fill in as much of the area as possible Bench Seat STEP 3 20 If covering a bench seat or step area not in a shower area place a single run of cable up the riser Use CableStrap or attachment membrane to secure the cable to the seat 14 of 32 area at the desired spacing then install a single run down the riser Use an s shaped curve to avoid sharp bends in the cable at corners and help the cable to
13. cable down the riser if needed Use an s shaped curve to avoid sharp bends in the cable at corners and help the cable to lay flat STEP 3 26 If the cable cannot exit the shower area the end of the cable has a waterproof splice that may be located in the shower area fully embedded into the mortar like the heating cable STEP 3 27 If any part of the heating cable entering a shower area is damaged during installation do not attempt to repair it A field repair or modification of the cable may result in serious shock hazard Final Steps STEP 3 28 After the cable installation is completed inspect the work Make sure all tabs are pressed down cable spacings are correct no cables cross over each other all the cables are undamaged and all areas to be heated are covered with cable STEP 3 29 Take resistance readings of the cable again to make sure it has not been damaged during the installation This is very important to do Record these readings in the Cable and Sensor Resistance Log Table 4 STEP 3 30 Lay cardboard carpet or similar material over the cables to protect them from damage until the floor covering is installed IOM WYF WW 1528 16 of 32 Phase 4 Finish Wiring STEP 4 1 Feed the power leads from the cable up through the hole drilled in the baseplate or up into the conduit to the control electrical box or junction box if one was used STEP 4 2 Below the control or wherever the floor sensor is to b
14. ccccsssseees 5 Phase 7 Install Insulation 008 20 Phase 2 Electrical Rough in 006 9 Appendices cccssessceceeeessssseeeeeeesssseees 20 Phase 3 Install the Cables 008 11 Troubleshooting scisseccicccnicacedenisucenceseddecsase 29 Phase 4 Finish Wiring s es 17 NVI AIWY A E TS 31 Phase 5 Control Installation 0 18 Important Safety Information with a signal word DANGER WARNING or CAUTION a pictorial and or a safety message to identify hazards When you see this symbol alone or with a signal word on your equipment or in this Manual be alert to the potential for death or serious personal injury of This pictorial alerts you to electricity electrocution and shock hazards A WARNING This symbol identifies hazards which if not avoided could result in death or serious injury A CAUTION This symbol identifies hazards which if not avoided could result in minor or moderate injury This symbol identifies practices actions or failure to act which could NOTICE result in property damage or damage to the equipment This is a safety alert symbol The safety alert symbol is shown alone or used J 3 of 32 2015 Watts Water Technologies Table 1 A WARNING zo As with any electrical product care should be taken to guard against the potential risk of fire electric shock and injury to persons The following cautions must be observed NEVER
15. cord for any future needs 2015 Watts Water Technologies Phase 5 Control Installation STEP 5 1 If it has not already been done install an electrical box for the SunStat thermostat and SunStat Relay See Step 2 2 for details STEP 5 2 Read and follow the instructions included with the SunStat thermostat and SunStat Relay for complete connection instructions requirements and mounting STEP 5 3 Make any final connections to the circuit breaker or branch circuit source A WARNING Make sure 120 VAC is supplied to 120 VAC cables and 240 VAC is supplied to 240 VAC cables Otherwise dangerous overheating and possible fire hazard can result STEP 5 4 System Start Up After all controls are installed do not energize the system except to briefly test operation of all components no longer than 10 minutes Do not put the system into full operation until the tile or flooring installer verifies all cement materials are fully cured typically two to four weeks See mortar manufacturer s instructions for recommended curing time NOTICE Refer to the installation sheets provided with the controls for proper setting The system should now operate as designed Please leave this instruction manual SunStat Control instructions and copies of photos of the installed heating system with the end user NOTICE Most laminate and wood floor manufacturers specify their flooring should not be subjected to temperatures over 82 to 84
16. d remeasure the resistance If measurement shows an open or short circuit the cable has been damaged Record resistances between all wires and contact the manufacturer If measurement is just a little low or high room temperature has affected the resistance Make the room temperature 65 75 F 18 24 C or contact the manufacturer The resistance measurement could be from more than one cable wired in series or wired in parallel Either will provide false resistance readings Make sure resistance measurements are for only one cable at a time The multi meter may be set to the wrong scale The ohmmeter should typically be set to the 200 2000 scale For heating wire with resistance range higher than 200 ohms on the nameplate label set the meter to the 2000 ohm 2k scale Floor does not get warm Cable has been damaged Measure cable resistance Check for both open circuit and short circuit as detailed earlier in this manual If damaged record resistances between all wires and contact the manufacturer GFCI has tripped indicated by a light on the control or GFCI TRIP Check for loose wire connections Reset the GFCI on the control or circuit breaker If it trips again check for a short circuit in the cable as detailed earlier in this manual If cable is damaged record resistances between all wires and contact the manufacturer If cable is not damaged replace t
17. doorways next to toilets etc Cabinet vanities Draw the border right up to the toe kick Tubs and shower entries Draw the border about 3 from the edge of the tub or shower Walls Draw the border about 3 from the wall If required to help the cable fit better it may be drawn 4 to 6 from the wall since people do not generally stand this close to a wall anyway It may also be drawn closer but be careful that the cable will not be placed under any trimwork A WARNING e Keep the cable at least 6 from wax toilet rings e Do not run the cable under cabinets or fixtures that have no clearance under them e Avoid running the cable into a small closet or pantry The heat cannot escape and things can be laid on the floor blocking the heat and potentially overheating and causing a fire hazard STEP 3 3 Make Sure the Cable Fits Check the cable size to ensure it will fit inside the Heated Area at the selected wire spacing A WARNING Remember the heating cable length CANNOT be cut to fit It must be kept its original length and fully embedded in the mortar in the floor Any modification or mis use of the heating cable will void the warranty and cause potential shock or fire hazard STEP 3 4 Decide the Layout Decide which direction the cables will run on the floor for the easiest coverage Refer to the sample layouts in this manual for assistance Depending on the shape of the area it may help to think of it in terms
18. e located measure at least 1 ft into the heated area Mark the spot where the sensor will be attached to the floor Be sure to locate the sensor exactly between two of the heating cables Sensor over RPM Mat UJJ E INI NM NV NTN Sensor over Schluter DITRA HEAT Membrane or Prodeso Heat Membrane 17 of 32 STEP 4 3 To make sure the sensor tip does not create a high spot in the floor it may be necessary to chisel a channel into the floor and lay the sensor tip into the channel Hot glue the tip into place Sf h STEP 4 4 Feed the sensor wire up to the control box Finish by securing a steel nail plate over the wires to protect them against baseboard nails later q Hi i STEP 4 5 If it was necessary to end a power lead at a junction box feed 14 or 12 gauge electrical wire from this box to the control box Tip If more than one cable was installed label the ends of the power leads with a brief description as to which area they supply power Use tape to label them Cable 1 Cable 2 Kitchen Bath or similar This will make it easier to identify the leads later on Take photos of the installation This will provide a useful re
19. es for wire gauge size STEP 2 2 SP single pole DP double pole Install Electrical Boxes SunStat Thermostat Install an extra deep electrical box for the SunStat Thermostat Follow the instructions included with the thermostat for complete information on location and wiring SunStat Relay Install an extra deep electrical box for any SunStat Relay s The SunStat Relay is used when more than 15 amps must be controlled by one SunStat Thermostat Follow the instructions included with the SunStat Relay for complete information on location and wiring Junction Boxes lf a cable is to be located so its power lead is not long enough to reach the SunStat thermostat or SunStat Relay directly a junction box must be installed Do not attempt to make a connection to other wiring without a junction box Use a standard junction box with a cover mounting it below the subfloor in the attic in the wall or in another location easily accessible after all coverings are complete If the SunStat sensor wire is not long enough to reach the SunStat thermostat directly it may be extended A junction box may be required by local code to make this connection Follow the installation instructions included with the SunStat for details For construction with an existing wall or where the wall is covered cut the necessary openings to mount the electrical boxes listed above Wait to install the boxes until all wiring is fed into these locations to make it easier
20. framed floor construction One zone 120 volts One cable 35 ft of CableStrap or two 25 ft rolls CableStrap Cable end Install cables at least 6 away from toilet rings 1 spool 100 ft 3 spacing Control Floor Sensor counter open to floor Master Bathroom normal heat loss framed floor construction One zone 120 volts One cable 24 ft of strap or one 25 ft roll Cable end CableStrap Toilet Install cables at least 6 away from toilet rings Shower O Bath Tub Floor Sensor Control 25 of 32 2015 Watts Water Technologies Master Bathroom normal heat loss framed floor construction One zone 120 volts One cable 49 ft of CableStrap or two 25 ft rolls Floor Sensor Control counter open to floor CableStrap ZZ LL 1 spool 2 Install cables 90 ft atleast 6 away Cable end 3 spacing from toilet rings BathTub Master Bathroom normal heat loss framed floor construction One zone 120 volts One cable 11 ft of CableStrap or one 25 ft roll Cable end Install cables at least 6 away from toilet rings et Bath Tub CableStrap Floor Sensor Control IOM WYF WW 1528 26 of 32 Basement Bathroom high heat loss below grade basement slab One zone 120 volts One cable 39 ft of CableStrap or two 25 ft rolls 1 spool 59 ft 2 5 spacing a id Control Floor Vanity Sensor O Cable end
21. g Mortar Applications These are appropriate applications if installing engineered wood vinyl laminate or carpet floor coverings Attach the WarmWire to the subfloor or slab then pour self leveling mortar 1 4 to 1 2 thick according to manufacturer s specifications Install floor covering after the mortar has cured Special Precautions Isolation Membrane Install the heating wire above the membrane whenever possible unless recommended otherwise by the membrane manufacturer Insulation Insulation dramatically enhances the performance and efficiency of floor warming systems Do not install rigid insulation directly above or below backer board or mortar Mosaic Tile When installing mosaic tile it is recommended to apply a two step process First embed the heating wire in a thin self level mortar bed 1 4 3 8 then thin set the mosaic tile according to typical practice Expansion Joints Do not install heating wires through an expansion joint Install heating wire right up to the joint if necessary but not through the joint A CAUTION Never bang a trowel on the Heating Wire to remove excess mortar from the trowel This could damage the heating wire IOM WYF WW 1528 20 of 32 Double plywood over frame floor Tile stone or laminate flooring Latex Portland cement mortar bond coat Heating cable Plywood Plywood subfloor Insulation per International Residential Code Chapter 11 Joist Cement backe
22. he GFCI control Also see GFCI conflicts below Incorrect voltage supplied or mismatched electrical components used Measure line voltage 120 VAC cables have black and white leads 240 VAC cables have black and blue leads Uninsulated concrete slab floor Surface temperatures rise slowly on an uninsulated slab and heat is lost to the ground below If after 5 to 8 hours of heating the floor is not warmer to the touch check for cable damage see Cable has been damaged above Measure load voltage amperage to cable Cables are wired in series or daisy chained end to end Multiple cables must be connected in parallel or black to black white to white 29 of 32 2015 Watts Water Technologies Problem Possible Cause Solution i Make sure wiring connections are correct Consult ed UA the wiring diagram on the back of the control the Floor heats ed p Ower SUDD instructions that came with the control or the continuously p ppiy wiring diagrams in Appendix 2 Defective control Return control to dealer for replacement If a programmable control the Carefully read and follow control programming programming may be incorrect instructions Incorrect voltage supplied or Test voltage verify parts See Incorrect voltage mismatched components used supplied section R Floor sensor is not wired properly Make sure only one floor sensor is connected to
23. hese diagrams are given only as examples of how to properly connect multiple cables Care must be taken not to overfill a box Be sure to use wire nuts that are the correct size for the connections being made Follow all codes for wiring All electrical work must be done by a qualified licensed electrician in accordance with local building and electrical codes and the National Electrical Code NEC especially Article 424 of the NEC ANSI NFPA70 and Section 62 of CEC Part 1 IOM WYF WW 1528 22 of 32 gt O gt 14 A Q z 3 dp ge G 0 Q Q lt Kitchen and Family Room normal heat loss slab on grade with insulation Two zones 240 volts Three cables 190 ft of CableStrap or eight 25 ft rolls CableStrap 3 5 e 2 K of 4a u 8 v vs vg Su 8 Q CGC G G G w QO Q O G C cc Q nu nN O U So SoS we O oO Wo U Am NN NU N Nn st E T Counter top and cabinetry ad te be Oe Oe Sd Sd Sd 87 3 spacing Cable end 2015 Watts Water Technologies 23 of 32 Kitchen and SunRoom normal and high heat loss framed floor construction One zone 240 volts Two cables 104 ft of CableStrap or five 25 ft rolls Cable end 1 spool 120 ft 3 spacing Control CableStrap 2 5 spacing 1 spool 118 ft DZA Wy lin SS N Cable end 24 of 32 IOM WYF WW 1528 Master Bathroom normal heat loss
24. hms 14 4 watts ft 12 watts ft 10 3 watts ft ft 240020 17 20 24 78 1 0 217 267 240030 25 30 36 117 1 5 143 176 240040 34 40 48 157 2 0 107 132 240050 42 50 60 196 2 5 84 104 240060 J 60 12 235 3 0 67 83 240070 59 70 84 274 3 5 59 73 240080 67 80 96 313 4 0 50 63 240090 76 90 108 352 4 5 45 56 240100 84 100 120 391 5 0 40 50 240120 101 120 144 470 6 0 33 42 240140 118 140 168 548 7 0 29 37 240160 135 160 192 626 8 0 24 31 240180 151 180 216 704 9 0 22 28 240200 168 200 240 783 10 0 20 26 NOTICE It is important to select the proper size cable for the given area WarmWire cannot be cut shorter in order to fit a given area Doing so will damage the heating wire and prevent the system from working IOM WYF WW 1528 6 of 32 A WARNING gt To prevent the risk of personal injury and or death make sure power is not applied to the product until it is fully installed and ready for final testing All work must be done with power turned off to the circuit being worked on STEP 1 1 Remove the WarmWire SunStat thermostat and SunStat sensor from their packages Inspect them for any visible damage Verify everything is the correct size and type according to the plan and the order Do not attempt to install a damaged product STEP 1 2 Record the product information There is a factory applied nameplate label on the power leads Do not remove this
25. in the bottom of the thermostat box Feed the sensor and conduit if used through the knock out down through the cut out in the bottom plate and out into the floor where the heating cable will be installed If the sensor wire needs to be secured to the wall stud wait until after the cable and sensor are completely installed on the floor STEP 2 5 Rough in Wiring Install appropriate 12 or 14 AWG electrical wire from the circuit breaker or branch circuit source to the SunStat Thermostat electrical box and SunStat Relay box es if needed following all codes see Table 5 If SunStat Relay s are used feed appropriate wire See SunStat Relay installation manual for size and type between the SunStat Relay s and the SunStat thermostat See SunStat Relay instructions for details of wire size and type IOM WYF WW 1528 10 of 32 Phase 3 Install the Cables STEP 3 1 Floor Cleaning The floor must be completely swept of all debris including all nails dirt wood and other construction debris Make absolutely sure there are no objects on the floor which might damage the wire Wet mop the floor at least twice to ensure there is no dirt or dust This will allow proper bonding of the mortar and proper stick of any adhesives or double sided tape used later STEP 3 2 Outline the Heated Area Use a marker to outline the area where the heating cable will be installed This includes any cabinet base or fixture not already installed across
26. istance to temperature values Ground for reference Lead White or Blue Lead Table 3 Floor Sensor Resistance Values Temperature Typical Values 55 F 13 C 17 000 ohms 65 F 18 C 13 000 ohms 75 F 24 C 10 000 ohms 85 F 29 C 8 000 ohms 7 of 32 2015 Watts Water Technologies Table 4 Cable and Sensor Resistance Log Cable 1 Cable 2 Cable 3 Cable serial number Cable model Cable voltage Factory cable resistance range OUT OF THE BOX BEFORE INSTALLATION OHMS Cable black to white black to blue for 240VAC Cable black to ground Cable white to ground blue to ground for 240VAC Sensor wire AFTER CABLE AND SENSOR ARE FASTENED TO FLOOR OHMS Cable black to white black to blue for 240VAC Cable black to ground Cable white to ground blue to ground for 240VAC Sensor wire AFTER FLOOR COVERINGS ARE INSTALLED OHMS Cable black to white black to blue for 240VAC Cable black to ground Cable white to ground blue to ground for 240VAC Sensor wire Retain this log to retain the warranty Do not discard INSTALLATION NOTES IOM WYF WW 1528 8 of 32 Phase 2 Electrical Rough in A WARNING gt To prevent the risk of personal injury and or death make sure power is not applied to the product until it is fully installed and ready for final testing All work must be d
27. label Record the cable serial number model number voltage and cable resistance range in the Cable and Sensor Resistance Log Table 4 If installing more than one cable do this for each of them STEP 1 3 Use a digital multi meter set to the 2000 or 20000 2kQ range to measure the resistance between the conductors of the cable power leads Record these resistances in Table 4 under Out of the box before installation The resistance should measure within the resistance range on the nameplate label If it is a little high or low it may be due to air temperatures or meter calibration Consult the factory if in doubt Measure the resistance between either of the white or black leads and ground lead This measurement should be open usually indicated by an OL ora I This is the same as displayed when the test leads are not touching anything NS Ss f 200 ohm sy setting White or Blue Lead If there is any change in the reading record this information and contact the factory before continuing This could indicate damage test lead problems or a number of other issues Try pinning the test leads to the cable lead wires against a hard non metal surface if the readings continue to fluctuate Change the meter to the 20 000 ohms 20 KO range Measure between the lead wires of the SunStat sensor This resistance varies according to the temperature sensed Table 3 provides approximate res
28. lay flat Again the cable on the riser and seat area MUST be fully embedded in mortar and have approved floor coverings Use hot glue where necessary to secure the cable flat against the riser Shower area installation This application into a shower area must be verified by the local inspector or the authority having jurisdiction AHJ STEP 3 21 Cables only with W on the nameplate label may be installed into a floor or bench seat located in a shower area It must never be installed into walls In general the cable should be completely embedded into mortar directly below the surface coverings of tile or stone Other types of coverings are not recommended It may be installed into a mortar layer lower than this and beneath the waterproof system however performance will be reduced See the Appendix for an example of this type installation It is recommended that a dedicated cable be installed in the shower area separate from the rest of the bath floor In case there is ever a problem with the shower installation this cable could be disconnected without loss of heat to the rest of the floor STEP 3 22 Make sure the power lead factory splice the connection between the power leads and the heating cable is located outside the shower area and at least 1 away from shower openings and other similar areas normally exposed to water Make sure the control is located at least 4 away from shower openings such that it cannot be exp
29. lue craft grade e Wire strippers e Phillips screwdriver e Fish tape e Hole saw e Floor covering installation tools Floor sensor is included in the thermostat packaging This must be installed in the floor with the cable 5 of 32 2015 Watts Water Technologies Table 2 Cable sizes all Models with suffix WB amp WR Please check the product label for exact ratings This table is for reference only The coverage areas given are for use with CableStrap only Contact the factory if using alternate attachment materials that may require different wire spacing 120 VAC Model Total Sq ft Total Sq ft Total Sq ft Wire Amp Resistance Number 2 5 Spacing 3 Spacing 3 5 Spacing Length Draw ohms 14 4 watts ft 12 watts ft 10 3 watts ft ft 120010 8 10 12 39 1 0 108 134 120015 13 15 18 59 1 5 72 89 120020 17 20 24 78 2 0 53 66 120025 21 25 30 98 2 5 42 52 120030 25 30 36 117 3 0 33 42 120035 29 35 42 137 3 5 29 37 120040 34 40 48 157 4 0 25 32 120045 38 45 54 176 4 5 22 28 120050 42 50 60 196 5 0 20 26 120060 Dt 60 l2 235 6 0 16 21 120070 59 70 84 274 7 0 14 19 120080 6 80 96 ole 8 0 12 16 120090 76 90 108 352 9 0 11 14 120100 84 100 120 391 10 0 10 13 240 VAC Model Total Sq ft Total Sq ft Total Sq ft Wire Amp Resistance Number 2 5 Spacing 3 Spacing 3 5 Spacing Length Draw o
30. more information www watts com prop65 IOM WYF WW 1528 30 of 32 Electric Floor warming Products 25 year Limited Warranty SunTouch and Watts Radiant the Companies warrant their respective electric floor heating mats and cables the Products to be free from defects in materials and workmanship for twenty five 25 years from the date of manufacture Thermostats and controls sold by the Companies are warranted parts and materials for two 2 years from the date of purchase The sole remedy for controls is product replacement This warranty is only provided to customers who purchase the Products from authorized resellers and is transferable to subsequent owners of properties where the Products are initially installed Under this Limited Warranty the Companies will provide the following If the Product is determined by the Companies to be defective in materials and workmanship and has not been damaged as a result of abuse misapplication or modification the Companies will refund all or part of the manufacturer s published list price of the Product at the time of purchase in accordance with the following 100 for the first ten 10 years then prorated ona diminishing 25 year scale for the remaining warranty period For example 1 Product found defective in the 5th year will receive the full manufacturer s published list price of the Product at the time of purchase 2 Product found defective in the 15th year with
31. not use rubber backed products When placing furniture make sure an air clearance of at least 1 1 2 is available Furniture able to trap heat can damage the heating system the flooring and the furniture over time e After floor coverings have been installed take resistance readings of the cable again to make sure it has not been inadvertently damaged Record these readings in the Cable and Sensor Resistance Log Table 4 19 of 32 2015 Watts Water Technologies Phase 7 Install Insulation Insulate under the subfloor for better performance and efficiency of the system Refer to the Appendix for diagrams and insulation recommendations Appendix 1 Types of Construction and Applications Type of Construction Mortar Applications Thin set and thick set self leveling mortar applications are illustrated to the right 1 If a backer board or plywood sheeting is used to strengthen the floor or if the heating wire will be placed directly onto the slab install in the thin set mortar bond coat above these materials 2 Ifa thicker mortar bed or self leveling concrete is used to strengthen the floor the heating wire can be installed in either the mortar bed dry set or in the mortar bond coat directly below the tile or stone The heating wire is generally installed above the self leveling mortar in a thin set bond coat Use plastic lath instead of the typical metal lath when installing in a self leveling layer Self levelin
32. ompanies assume no responsibility under this warranty for any damage to the Product caused by any trades people visitors on the job site or damage caused as a result of post installation work The staff at the Company is available to answer any questions regarding the proper installation or application of the Product at this toll free phone number 800 276 2419 If you are ever in doubt about the correct installation procedure to follow or if the Product appears to be damaged you must call us before proceeding with the installation or proposed repair 31 of 32 THE COMPANIES DISCLAIM ANY WARRANTY NOT PROVIDED HEREIN INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE THE COMPANIES FURTHER DISCLAIM ANY RESPONSIBILITY FOR SPECIAL INDIRECT SECONDARY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM OWNERSHIP OR USE OF THIS PRODUCT INCLUDING INCONVENIENCE OR LOSS OF USE THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE OF THIS DOCUMENT NO AGENT OR REPRESENTATIVE OF THE COMPANIES HAS ANY AUTHORITY TO EXTEND OR MODIFY THIS WARRANTY UNLESS SUCH EXTENSION OR MODIFICATION IS MADE IN WRITING BY A CORPORATE OFFICER DUE TO DIFFERENCES IN BUILDING AND FLOOR INSULATION CLIMATE AND FLOOR COVERINGS THE COMPANIES MAKE NO REPRESENTATION THAT THE FLOOR TEMPERATURE WILL ACHIEVE ANY PARTICULAR TEMPERATURE OR TEMPERATURE RISE UL STANDARD LISTING REQUIREMENTS LIMIT THE HEAT OUTPUT OF REGULA
33. one with power turned off to the circuit being worked on STEP 2 1 Circuit Breaker Overcurrent Protection WarmWire must be protected against overload by a circuit breaker GFCI type ground fault circuit interrupter or AFCI type arc fault circuit interrupter breakers may be used if desired but are not necessary when using SunStat controls with integral GFCI The rating of the breaker see Table 5 is determined by the amp draw of the heating cables Add the amp ratings of all cables to be connected to the SunStat control see Table 2 or the Nameplate Label on the cable If the total is less than 12 amps use a 15 or 20 Amp breaker preference is 15 A If the total is between 12 and 15 amps use a 20 Amp breaker If the total is over 15 A another circuit will be required with its own breaker and SunStat control Table 5 It may be possible to tap into an existing circuit as long as there Circuit Breakers and Supply Wire is adequate capacity for the Cable s Supply Wire Breaker cables s and any additional ap VAC total amps AWG qty type rating pliance such as a hair dryer or 120 uptoizamps 14 1 SP 150r20A vacuum cleaner Avoid circuits 120 up to 15 amps 19 J Sp 50 A which have lighting motors exhaust fans or hot tub pumps 240 up to 12 amps 14 DP 150r20A due to possible interference 240 upto 15 amps 12 1 DP 20A Recommended only Follow local cod
34. oor clearance or in small closets Excessive heat will build up in these confined spaces and the wire can be damaged by fasteners nails screws etc used to install built ins NEVER remove the nameplate label from the power leads Make sure it is viewable for inspection later NEVER extend the heating wire beyond the room or area in which it originates NEVER allow a power lead or sensor wire to cross over or under a heating cable Damage could result l ALWAYS completely embed the NEVER put the system into full operation until the tile or flooring factory splice and all heating installer verifies all cement materials are fully cured typically two wire in mortar NEVER bend the splice or place any part of it in to four weeks the wall or through the floor ALWAYS ALWAYS completely embed the heating wire and factory splices in the floor mortar ALWAYS maintain a minimum of 2 5 spacing between heating wires ALWAYS pay close attention to voltage and amperage requirements of the breaker the thermostat and the WarmWire For instance do not supply 240 VAC power to 120 VAC WarmWire as damage will result ALWAYS test the wire before and after installation IOM WYF WW 1528 4 of 32 ALWAYS make sure all electrical work is done by qualified persons in accordance with local building and electrical codes Section 62 of the Canadian Electrical Code CEC Part and the National Electrical Code NEC especially Article
35. osed to water or touched by a person in the shower area STEP 3 23 If the heating cable must enter the shower area over a curb secure the cable at the edges in an s shaped curve to ensure the cable is not bent sharply or pinched when surface coverings are installed Do not damage any waterproofing components and do not run the heating cable through a non masonry curb causing it to overheat Sj I Lt F f A W on the nameplate label indicates a WarmWire cable Ps is approved for installation in shower floors and or benches SunStat Thermostat aa iT a Factory Splice Floor Sensor Thin Set Mortar WarmWire CableStrap Tile Stone 15 of 32 2015 Watts Water Technologies STEP 3 24 If covering a shower floor cut lengths of strap and secure to the floor with adhesives Do not use fasteners that penetrate any waterproofing membrane or waterproofing system Fill in the floor area with cable Around the drain leave at least 2 spacing from the edge of the flange Make sure cable is not placed where door hardware handrails or other items may mount to the floor STEP 3 25 If covering a bench seat in the shower cut lengths of strap and secure to the top surface of the seat with adhesives Do not use fasteners that penetrate any waterproofing membrane or waterproofing system Use hot glue to secure a single run of cable up the side of the bench riser Fill in the seat area with cable Then secure a single run of
36. r additional information on tile installation please contact TCNA at 864 646 8453 or visit their web site at www tileusa com or contact NTCA at 601 939 2071 or see their web site at www tile assn com When installing floor coverings other than tile or stone follow industry and or manufacturers recommendations Ensure the wire is first covered with a layer of self leveling cement based mortar letting it cure fully before applying any surface underlayment floating wood or laminate flooring carpet etc The combined R values of all floor coverings over the wire should not exceed R 3 Higher R values will diminish performance Consult the floor covering manufacturer to verify compatibility with radiant electric heat Make sure nails screws or other fasteners do not penetrate the floor in the heated area The wire can easily be damaged by fasteners penetrating the floor All floor coverings must be in direct contact with the cement based mortar encasing the wire Do not elevate the floor above the mortar mass Do not install 2 x 4 wooden nailers sleepers on top of a slab for the purpose of attach ing hardwood Any air gap between the heating wire and the finished floor covering will drastically reduce the overall output of the heated floor Care should be taken when laying area rugs throw rugs and other surface products on the floor Most products are okay to use but if in doubt consult the product manufacturer for compatibility Do
37. rboard over frame floor Tile stone or laminate flooring Latex Portland cement mortar bond coat Heating cable Cement backerboard thick set or selfleveling mortar bed Plywood subfloor Insulation per International Residential Code Chapter 11 Joist Thin set over slab on grade Tile stone or laminate flooring Thin set or self leveling mortar bed Heating cable Antifracture membrane or cork underlayment as needed Concrete slab with rewire or rebar Insulation beneath slab per International Residential Code Chapter 11 21 of 32 2015 Watts Water Technologies Connecting Multiple Cables A WARNING To prevent the risk of personal injury and or death do not perform any electrical work unless qualified to do so Work should be done with great care and with power turned off to the circuit being worked on Follow all local building and electrical codes SunStat Relay Connections Standard NM Cable 12 or 14 AWG Power Supply 120 VAC or 240 VAC Power Power Lead From Lead From Multiple cables can be connected to WarmWire WarmWire a single SunStat or SunStat Relay II Refer to Table 2 and Table 5 for details on calculating the maximum number of cables per control or relay Cable 1 Cable 2 N Y S S WarmWire Connections Junction Box Near Cables A WARNING The SunStat is not fully illustrated in these diagrams in order to simplify them T
38. rcuit load 15 amps Maximum circuit overload protection 20 amp breaker GFCI Ground Fault Circuit Interrupter required for each circuit included in the SunStat control Listing UL Listed for U S and Canada under UL 1673 and CAN CSA C22 2 No 130 2 93 File No E185866 Application Indoor floor heating only X on the nameplate label indicates CUL Listing for this application Suitable for installation in a shower area see Step 3 19 for restrictions W on the nameplate label indicates CUL Listing for Wet Location in Canada per Canadian Electrical Code Part CEC Embedded in polymer modified cement based mortar only see Appendix 1 Minimum bend radius 1 inch Factory Splice Maximum exposure temperature continuous and storage 194 F 90 C Heating Minimum installation temperature 50 F 10 C Wire End Splice Power Lead Installation must be performed by qualified persons in accordance with local codes ANSI NFPA 70 NEC Article 424 and CEC Part 1 Section 62 where applicable Prior to installation please consult the local codes in order to understand what is acceptable To the extent this information is not consistent with local codes the local codes should be followed However electrical wiring is required from a circuit breaker or other electrical circuit to the control It is recommended that an electrician perform these installation steps Please be aware local codes may require this product and or
39. ter Technologies
40. the correctly or is not working properly control Loose connection s on line side and or load side of control Remove and reinstall the wire nuts at each connection Make sure the wire nuts are tight Check all connections back to the breaker Defective control Return control to dealer for replacement Control is not working at all No power is supplied Check circuit breaker Measure voltage at the on Check all connections between breaker and control Floor sensor is not wired properly or is not working properly Defective control Make oe only one floor sensor is connected to the control Return control to dealer for replacement GFCI conflicts and false trips An electric motor or a ballasted light source is sharing the circuit with the cable s Electric motors and similar electrical devices can cause a GFCI to false trip Run a dedicated circuit to the floor warming system or select a different branch circuit Although this troubleshooting guide is provided to assist with problems experienced with a floor warming system results are never guaranteed The company does not assume any liability or responsibility for damage or injury that may occur from using this guide If problems with the system persist call the manufacturer WARNING This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm For
41. ver allow any part of the Factory Splice or heating cable to enter a wall or cabinet or drop through the subfloor Damage to the product will result Install Cable Attachment Membrane STEP 3 8 If using Schluter DITRA HEAT Membrane Prodeso Heat Membrane or RPM mat read and follow completely the installation instructions given with that product Ensure that all cautions and warnings are followed and that the product is well bonded to the floor before continuing Position the Power Leads amp Factory Splice STEP 3 9 Carefully cut the tie binding the power lead coil Do not nick the braid covering the power lead Locate the Factory Splice to ensure the power lead will reach the SunStat electrical box or junction box location It is acceptable to run the power leads several feet in the floor area embedded in mortar if needed STEP 3 10 Draw an outline around the Factory Splice and move it aside Chisel a shallow channel to allow the Factory Splice to lay flat with the rest of the heating cable in the channel Add hot glue in the channel and set the Factory Splice in place Factory splice 13 of 32 Installing Cables on CableStrap STEP 3 11 Weave the cable back and forth across the area at the desired spacing until the other side of the room has been reached Once this area is completed press down all the tabs 2 5 spacing a e l Y o 3 spacing j
42. warmyour floor the radiant floor heating experts ar WarmWire Installation Manual Series Assembled in the WB amp WR USA U A WARNING Please be aware local codes may require this product and or the thermostatic control to be installed or connected by an electrician A WARNING WarmWire is a simple economical way to warm any floor and provide years of lasting comfort This instruction manual provides complete details suggestions and safety precautions for installing this floor warming system Read this Manual BEFORE using this equipment Failure to read and follow all safety and use information can result riety in death serious personal injury property damage or damage to the equipment Keep this Manual for future reference Fasten the cables to the floor Then depending on the floor coverings to be used put down a layer of thin set thick set or self leveling mortar on top of the cables Finally install the floor coverings It s that simple Specifications for WarmWire WarmWire is a complete heating cable consisting of a series resistance heating cable anda power lead for connection to the electric power supply The heating cable cannot be cut to fit Voltages 120 VAC 240 VAC 1 phase Watts 10 3 W saft 84 Btu h saqft when spaced 3 1 2 inches on center up to 14 4 W saft 51 Btu h saqft when spaced 2 1 2 inches on center See Table 2 Maximum ci
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