INSTALLATION MANUAL
Contents
1. normal heat loss framed floor construction One zone 120 volts 1 spool 2 1 2 spacing Toilet Install cables at least 6 away from toilet rings L termination Strap T amp 2 Shower 1 spool Install cables at least 6 away from toilet rings Bath Tub Floor Sensor O 1 spool 2 1 2 spacing Closet Ce Dual Vanity Ce 7 Control Floor Sensor 1 spool 2 1 2 spacing Spool termination Bath Tub 22 HeatStep Wire Installation Manual Basement Bathroom high heat loss below grade basement slab One zone 120 volts 1 spool 2 spacing 1 spool 2 spacing Control Floor Sensor Vanity Closet Vanity Shower O Bath Tub Master Bathroom normal heat loss framed floor construction One zone 120 volts 1 spool 2 1 2 spacing Spool termination Install cables at least 6 away from toilet rings Bath Tub Sec Toilet Closet Strap Floor Sensor 1 spool Spool termination Strap HeatStep Wire Installation Manual 23 Master Bathroo2. HeaiSiens aX INSTALLATION MANUAL 800 7Bostik 800 726 7845 Please be aware that local codes may require this product and or the control to be installed or connected by an electrician Please leave this manual with the end user 2 HeatStep Wire Installation Manual Welcome to HeatStep Wire HeatStep Wire is a simple economical way to warm any floor and provide years of lasting comfort This instruc tion manual provides complete details suggestions and safety precautions for installing this floor warming system 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 Table of Contents Phase 1 Design the System 005 3 Phase 2 Preparation ccc cee eeeee eens 4 CAUTIONS oni ceca me dd bee dd ed bad enocaebenebe cede 4 WPS i eicrvinaiatdeaseteaaekensietaakeeneenedaunte 5 Items Needed ccc c cece eect ence ence ence 5 Phase 3 Inspect the Cable and Sensor 5 Cable and Sensor Resistance Log 05 6 Phase 4 Electrical Rough in 45 7 New Construction cece e cece nee e eens 7 Existing Construction cece cece eee eee eee 7 Phase 5 Install the Cable 00e eee 8 Getting Started eee eee e eee eee ene 8
3. Phase 7 Install the Control STEP 7 1 Read and follow the instructions that come with the HeatStep controls STEP 7 2 Refer to the wiring diagrams in this manual for different voltages and applications STEP 7 3 Install the electrical box for the control if this has not already been done Connect the power leads from the cable or the electrical wiring coming from junction boxes to the LOAD side of the control Connect the incoming power to the LINE side of the control Connect the sensor wires to the sensor terminals on the control Connect the ground leads from the system to the ground wire from the incoming power STEP 7 4 Install the control into its electrical box and turn the circuit breaker on to power the system Test the system and control for several cycles It should allow the heating cables to heat up correctly Note Consider placing a loose tile over the sensor tip to simulate warming the floor and allow the sensor to register this on the control STEP 7 5 Retain all instruction sheets and warranties Phase 8 Install the Floor Coverings STEP 8 1 Make a Final Inspection of the Installation Inspect the installation very carefully for evidence of damage or missing sensor s STEP 8 2 Select Type of Construction Choose the best thin set thick set or self leveling mortar method for the appli cation See Appendix 1 for reference It is recommended to consult with professional flooring installers
4. General Installation 00 cece eee eee ee 9 Other Installations 0 cc cece eee e eee 10 Final Step Sn e anann gad cenemee daw acd 11 Phase 6 Finish Wiring 0 12 New Construction cece eee cece cence ees 12 Existing COnSstructiOn eee e eee neces 12 Phase 7 Install the Control 065 13 Phase 8 Install the Floor Coverings 13 Phase 9 Install Insulation 665 13 Phase 10 System Operation 13 Appendix 1 Types of Construction 14 Appendix 2 Typical Electrical Wiring Diagrams 16 Appendix 3 Connecting Multiple Cables 18 Appendix 4 Connecting the Wire Fault Detector 79 Appendix 5 Sample Layouts 20 Troubleshooting Guide 0e ee eee 25 Specifications Installation Facts Skill level Installation must be performed by quali fied 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 rec ommended that an electrician perform these installation steps Please
5. consult local code Wire nuts if using a junction box Nail plate Polymer modified cement based mortar Tools e Digital multi meter for ohms testing must read up to 20 000 ohms Q to measure sensor Drill with 1 2 bit Hammer and chisel Wire strippers Phillips screwdriver Fish tape for existing construction e Hole saw for existing construction e Trowel plastic preferred with 3 8 notches or greater Phase 3 Inspect the Cable and Sensor WARNING 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 3 1 Take the cable out of the box and inspect it to make sure there is no 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 3 2 Record the product information There is a factory applied nameplate label on the power leads Do not remove this 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 6 HeatStep Wire Installation Manual IMPORTANT To retain the Limited Warranty the following measurements must be recorded and all steps of this manual followed STEP 3 3 Use a digital multi meter
6. ft of kitchen and Number 15 watts sq ft 12 watts sq ft 10 watts sq ft ft Draw ohms dining area to be warmed 640210 64 80 96 376 4 0 51 63 with 240 VAC The cableis K640212 80 10 120 470 50 41 51 7 K640214 96 120 144 564 6 0 34 42 to M 3 oie pro Ko40216 12 14 168 658 70 29 36 vice it watts sq Ty pro K640o280 128 160 192 752 8 0 25 32 viding warmth across the entire floor area As seen Note Other HeatStep Wire sizes avialable in both 120 VAC and in Table 1 choose Model Numbers K640212 and 240VAC upon request K640214 to end up with about 264 sq ft covered r Phase 2 Preparation NO Table 2 Cautions A CAUTION As with any electrical product care should be taken to guard against the poten tial risks of fire electric shock and injury to persons The following cautions must be observed NEVER install Heating wire under carpet wood vinyl or other non masonry NEVER bang a trowel or other fpern Be embedding it in Bostik SL 150 WebCrete 95 WebCrete 98 s or Ultra Finish tool on the heating cable NEVER install HeatStep wire 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
7. Cut another piece of strap for the other end of the area and secure 3 from the wall s or other obstruction s S lt 4 STEP 5 9 Unreel the power leads of the cable up to the factory splice Let the coil of power leads sit on the floor for now Beyond the factory splice is the heating cable itself Factory splice must be installed in the mortar bed CAUTION Completely embed the factory splices and heating cable in the mortar and never bend the fac tory splices NEVER allow any part of the splice or heating cable to enter a wall or drop through the subfloor STEP 5 10 Before installing more S NZ Z strap fill in the first section with cable Begin by making a strain relief at the beginning so the cable is not acciden tally pulled loose Zigzag the cable under the tabs only as shown Press the tabs down to secure the cable STEP 5 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 S 2 tabs NEVER space the cables less than 2 apart STEP 5 12 If there are additional areas to cover with cable cut the lengths of strap necessary attach them to the floor and begin weaving Za the cable into that area STEP 5 5 Measure about 3 from the wall for the strap In counter or vanity kick spaces install the strap so the cable will be 1 1 2 to 2 away
8. from the STEP 5 6 Cut the strap to fit the length of the first area Depending on the floor type differ ent methods may be used Refer to the instructions provided with the strap Plywood cement board or similar Galvanized nails or screws may be STEP 5 1 O g STEP 5 11 a Ji j Y l 10 HeatStep Wire Installation Manual STEP 5 14 Use a chalk line or pen STEP 5 17 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 STEP 5 13 For an angled area such as a corner shower first cut several pieces of strap a little longer than the cable spacing being used to mark the floor at 3 from the edge of the shower STEP 5 15 Use this chalk line to STEP 5 16 attach each piece of strap to the floor so that the cable does not get any closer to the corner shower than 3 Make sure that the cables are spaced evenly and parallel to one another STEP 5 16 Fill in the section with cable Door entryway STEP 5 17 For an entryway or other small area where warmth is required begin by cutting two lengths of strap a little shorter than the pari of the entry op
9. is too far to reach with the power lead wires it will also be necessary to mount a junction box where the lead wires can terminate Use a standard junction box with a cover mounting it below the floor in the attic or in another easily accessible location It must remain easily accessible and not located behind a cabinet or similar obstruction Then use 14 or 12 gauge NM type or other accepted electrical wiring to con nect from the junction box to the control electrical box STEP 4 12 At the floor level below the control box cut a 2 x 2 wide piece from the wall surface Use a wood chisel to notch out a channel in the baseplate to make it easier to route the wires up the wall STEP 4 13 Mark the circuit breaker in the panel which feeds the system with Floor warming bath or similar Phase 5 Install the Cables Getting Started IMPORTANT Refer to Phase 8 and Appendix 1 to make sure the floor is properly prepared for installation of the cable s especially the use of reinforcement leveling and insulation on concrete slab STEP 5 1 Use the sketch and design considerations made earlier in Phase 1 to begin laying the cables Do not install the cables closer than about 6 from wax toilet rings and plumbing to keep from over heating these items STEP 5 2 Make sure to space the cables to provide the warmth desired WARNING This heating cable CANNOT be cut shorter to fit Do not overlap or cross over heating cable on itsel
10. originates NEVER allow a power lead or sensor wire to cross over or under a heating cable Damage could result NEVER use less than 2 spacing ALWAYS completely embed the heating wire and factory splices in Bostik SL 150 WebCrete 95 WebCrete 98 or Ultra Finish ALWAYS maintain a minimum of 2 spacing between heating wires ALWAYS pay close attention to voltage and amperage requirements of the break er the thermostat and the HeatStep wire For instance do not supply 240 VAC power to 120 VAC HeatStep wire as damage will result 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 I and the National Electrical Code NEC especially Article 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 installa tion procedure to follow or if the product appears to be damaged the factory must be called before proceeding with the installation HeatStep Wire Installation Manual 5 Some Tips Trowel Use a plastic trowel to reduce the possibility of cable damage Insulation The better insulation that is provided the more efficiently the system operates and the better the floor is heated Concrete slab sur faces offer the most thermal drain and should be i
11. system Use a 120 VAC single pole breaker for a 120 VAC system Use a 240 VAC double pole breaker for a 240 VAC system For systems that are too large to directly power through one HeatStep Control but must be operated by one floor sensing control use a HeatStep Control in combination with up to 10 HeatStep Relay Controls Contact a HeatStep dealer or the factory for more informa tion STEP 4 9 Cut an opening in the wall for the control electrical box If installing one to two cables use an extra deep single gang box to allow plenty of room for the wiring Use a 4 square box if installing three cables The box can be located almost anywhere that is well venti lated However the best place is in the same room as the cable typical ly about 60 above the floor and within reach of the power lead wires of the cable If installing more than three cables it will be necessary to connect their power leads in a junction box first see Step 4 11 to keep from overfilling the control box Then route one power supply from this junction box to the control box See Step 5 22 for special requirements if the control will connect to a heating cable entering a shower area STEP 4 10 Following code feed 14 or 12 gauge NM type electrical wiring from the circuit breaker panel to the control electrical box opening Leave about 6 8 of extra wire extended from the opening STEP 4 11 If the control box must be mounted in a location that
12. the floor STEP 5 21 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 exposed to water or touched by a person in the shower area STEP 5 22 If the heating cable must enter the shower area over a curb notch the corners of the curb with a minimum 1 wide notch to ensure the cable is not bent sharply or pinched when surface coverings are HeatStep Wire Installation Manual 11 installed Do not damage any waterproofing components and do not run the heating cable through a non masonry curb causing it to overheat STEP 5 23 If covering a shower floor cut lengths of strap and secure to the floor with adhe sives 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 5 24 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 sid
13. to make sure proper materials are used and prop er installation techniques are followed Please note this installation manual is not a structural or a floor covering installation manual and is intended only for general guid ance as it applies to the HeatStep Wire product When installing tile or stone the Tile Council of North America TCNA guidelines or ANSI specifications should be followed as a minimum standard Use Bostik SL 150TM WebCrete 95 WebCrete 98 or Ultra FinishTM Do not use water based multi purpose materials when installing a radiant product Do not use sol vent based adhesives or pre mix mortars because they are not as heat resistant and do not conduct heat well 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 For additional information on tile installation please con tact 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 manufacturer s recommendations Ensure the heating wire is first covered with a layer of SL 150 self leveling cement based mortar letting it cure fully before applying any surface unde
14. 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 6 3 Secure the power lead splice into the chiseled channels with hot glue STEP 6 4 Below the control or wherever the floor sensor is to be 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 STEP 6 5 To make sure the sensor tip does not create a high spot in the floor chisel a channel into the floor and lay the sensor tip into the channel Hot glue the tip into place STEP 6 6 Drill another hole into the baseplate if needed to feed STEP 6 4 L 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 STEP 6 7 If it was necessary to end g a power lead at a junction box feed 14 or 12 gauge electrical wire from this box to the control box WE Tip If more than one cable was SD installed label the ends of the power WANA Vy gt leads with a brief description as to N which area they supply power Use Dy tape to label them Cable 1 Cable ey vd 2 Kitchen Bath or similar This ret Hee will make it easier to identify the Ze leads later on Take photos of the STEP 6 installation This will provide a useful 3 record for any future needs 2 Ex
15. 240 VAC 240 VAC Heating Cables White Line 2 maximum 15 amps White Diagram for connection of signal wire between HeatStep Control and Relays 120 240 VAC 120 240 VAC 120 240 VAC HeatStep Control HeatStep Relay HeatStep Relay Up to 10 HeatStep Relays can be connected to one HeatStep Control Sensor O O Relout O O O Setback NOTE Installation must be performed by a qualified licensed electrician in accordance with local building and electrical codes ANSI NFPA 70 NEC Article 424 and CEC Part 1 Section 62 where applicable Observe polarity when connecting relays 18 HeatStep Wire Installation Manual Appendix 3 Connecting Multiple Cables NOTE The control is not shown in these diagrams in order to simplify them These 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 If in doubt consult an electrician Thermostat Control 4 x4 Electrical Box Thermostat Control 4 x4 Electrical Box NM Cable 240 VAC Wiring Legend L1 Red 4 NM Cable 120 VAC Wiring Legend L1 White 7 G Copper Es L2 Black ME G Copper EEEE 120 VAC Wiring Legend 240 VAC Wiring Legend G Ground HEE G Ground HE L1 White L L1 Blue C L2 bBlack ME L2 Black ME
16. Illustration showing how to connect three 4 x 4 Junction Box cables at the control electrical box L2 Biack ME 4 x 4 Junction Box DMV p 10 ZL 81920 WN Piepue s SMV PL 10 ZL 81929 WN PJepuels Power Lead Power Lead Power Lead Power Lead 120 VAC Wiring Legend 240 VAC Wiring Legend 120 VAC Wiring Legend 240 VAC Wiring Legend G Ground H G Ground E G Ground EE G Ground EEE L1 White C L1 Bue CZI L1 White 7 L1 Bue D L2 Black ME L2 Black ME L2 Black ME L2 Black ME Illustration showing how to connect multiple cables from multiple junction boxes at one control electrical box HeatStep Wire Installation Manual 19 Appendix 4 Connecting the Wire Fault Detector 120 VAC Wiring Legend G Ground L1 White L2 Black ME 240 VAC Wiring Legend G Ground L1 Blue L2 Black ME Use minimum 18 gauge wire to make short jumper wires Illustrations showing left how to connect the Wire Fault Detector to two cables and right how to connect the Wire Fault Detector to three cables The Wire Fault Detector can monitor no more than three cables simultaneously Do NOT leave the power leads connected in series like this when making final wiring connections the cables will not heat sufficiently 20 _ HeatStep Wire Installation Manual Appendix 5 Sample
17. Layouts Kitchen and Family Room normal heat loss slab on grade with insulation Two zones Kitchen Zone 1a 1 spool 2 1 2 spacing Zone 1b 1 spool 2 1 2 spacing Family Room Zone 2 1 spool 3 spacing Spool termination 1 spool 2 1 2 Aayauiqe gt pue do 4a un0 gt 1 spool Zone 1 Zone 1 Zone 2 Zone 2 1 spool 2 1 2 spacing Sensor Control Control Sensor 3 spacing Kitchen and SunRoom normal and high heat loss framed floor construction One zone 240 volts Kitchen 1 spool 3 spacing Sunroom 1 spool 2 spacing 1 spool Floor 3 spacing Control Sensor Counter cabinetry a in im Pantry Counter and cabinetry Strap Sink termination Lo IH Spool termination 1 spool 2 spacing i S AN termination Master Bathroom normal heat loss framed floor construction One zone 120 volts 1 spool 2 1 2 spacing HeatStep Wire Installation Manual 27 Bath Tub Install cables at least 6 away from toilet rings Strap Spool Master Bathroom normal heat loss framed floor construction One zone 120 volts 1 spool 2 1 2 spacing Control Floor Sensor 2 1 2 spacing Master Bathroom
18. Press the test lead tips to the Black and White or Blue for 240 VAC power lead Table 33 wires This reading should correspond to Floor Sensor Resistance Values the factory resistance range on the name Temperature Typical Values Black Lead plate label attached to the Power lead 55 F 13 C 17 000 ohms iomrmttdansese Sto meom and the White or Blue for an A s Ground power lead wires should measure 75 F 24 C 10 000 ohms open or O L or the same as displayed 85 F 29 C 8 000 ohms CG when the test leads are not touching anything Table 4 Cable and Sensor Resistance Log 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 AFTER CABLE AND SENSOR ARE FASTENED TO FLOOR ohms OSS Cable black to white black to blue for 240VAC Cable white to ground blue to ground for 240VAC a er 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 Install an extra deep single gang box if connecting one or two cables to the co
19. ance 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 the 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 Incorrect wiring The control was bypassed when it was wired to the power supply Multiple cables must be connected in parallel or black to black white to white Make sure wiring connections are correct Consult the wiring diagram on the back of the co
20. be aware local codes may require this product and or the control to be installed by an electrician Expected floor temperature The floor temperature attainable is depen dent on how well the floor is insulated the temperature of the floor before start up and in the case of uninsulated slab applications the thermal drain of the underlying materials These are the three most common installa tions 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 2 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 3 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 tempera ture that can be expected from the cables in any particular construction Please see Phase 9 Install Insulation on page 13 HeatStep Wire is a complete heating cable consisting of a series resistance heating cable and single power lead for easy single point connection The heating cable cannot be cut to fit Voltages 120 240 VAC 1 phase Wa
21. e of the bench riser Fill in the seat area with cable Then secure a single run of cable down the riser if needed STEP 5 25 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 heat ing cable STEP 5 26 If any part of the heating cable entering a shower area is damaged during instal lation do not attempt to repair it A field repair or modification of the cable may result in serious shock hazard HeatStep Control Factory Splice Thermostat Sensor Strap Thin Set Mortar Tile Stone HeatStep Wire cables only with W on the nameplate label installed in shower floors and or benches See Step 5 20 and Appendix 5 Final Steps STEP 5 27 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 cables in series STEP 5 28 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 floor Press the tabs down over the cables If a spray adhesive was not used carefully secure these short l
22. ed Record these readings in the Cable and Sensor Resistance Log Table 4 Phase 9 Install Insulation Insulate under the subfloor for better perfor mance and efficiency of the system Refer to the Appendix 1 for diagrams and insulation recom mendations Phase 10 System Operation After all system components 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 oper ation 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 NOTE Most laminate and wood floor manu facturers specify their flooring should not be subjected to temperatures over 82 F to 84 F 27 C to 28 C Check with the flooring dealer or manufacturer and set the thermostat Floor Limit temperature appropriately Refer to the installation sheets provided with the controls for proper setting The system should now operate as designed Please leave this instruction manual HeatStep Control instructions and copies of photos of the installed heating system with the end user 14 HeatStep Wire Installation Manual 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 a If a backer board o
23. engths of strap to the floor without damaging the cable STEP 5 29 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 5 30 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 5 31 optional With the heating portion of the cable fully installed it is recommend ed that the cable be temporarily connected to the power source and allowed to heat for several minutes After the cables begin to feel warm to the touch disconnect the power STEP 5 32 Lay cardboard carpet or similar material over the cables to protect them from damage until the floor covering is installed 12 HeatStep Wire Installation Manual STEP 6 11 Phase 6 Finish Wiring STEP 6 1 Chisel a channel into the floor to lay the factory splice into This will ensure the splice does not create a high spot in the floor CAUTION The power lead splice MUST BE FULLY EMBEDDED IN the mortar bed and never bend the factory splices NEVER allow any part of the splice or heating cable to enter a wall or drop through the subfloor New Construction STEP 6 2 Feed the power leads from the cable
24. ening Then secure the two straps parallel to each other STEP 5 18 Fill in with cable adjusting spacing as necessary to fill in as much of the area as possible Bench Seat STEP 5 19 If covering a bench seat or step area not in a shower area place a single run up the riser Use straps to secure the cable to the seat area at the desired spacing then install a single run down the riser 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 STEP 5 20 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 Pon 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 mor tar layer lower than this and beneath the waterproof system however performance will be reduced See Appendix 5 for an example of this type installation Consider installing a dedicated cable 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
25. f Do not space heating cables less than 2 apart Failure to do so may result in damage to the product and dangerous overheating STEP 5 3 If this is new construction draw lines on the floor or use tem plates to outline the area of any cabinets fixtures or future walls that will be placed in the room NEVER install the cables under cabinets fixtures or walls Excess heat may build up under these items and cause damage STEP 5 4 Decide which direction the cables will run on the floor for the easiest coverage Refer to the sample layouts in this manual ai for assistance Depending on the F o shape of the aes may nel NEVER use less than 2 spa to think of it in terms of several smaller areas HeatStep Wire Installation Manual 9 General Installation vanity base STEP 5 7 Secure the strap to the floor for full details used to secure the strap every 6 to 10 Concrete or similar Concrete nails 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 screw the strap down in several places to ensure it does not come loose If using a strong spray adhesive appl to path the packa the stra ond the floor where it will be placed and care fully follow all spray manufacturer s instructions and cautions STEP 5 8
26. 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 parts and methods NEVER splice one heating wire to another to make it longer Multiple heating wire power leads must be connected in parallel in a junction box or to the thermo ALWAYS stat NEVER install one heating wire on top of another or overlap the heating wire on Always completely embed the itself This will cause dangerous overheating factory splice and all heating wire NIREO CAA AeA o A AEA OEA in mortar NEVER bend the splice NEVER install HeatStep wire in any walls or over walls or partitions that extend or place any part of it in the wall to the ceiling or through the floor NEVER install heating wire under cabinets or other built ins having no floor clear 7 ance or in small closets Excessive heat will build up in these confined spaces N O NEVER use 1 spacing and the heating wire can be damaged by fasteners nails screws etc used to J install built ins NEVER remove the nameplate label from the power leads Make sure it is view able for inspection later NEVER extend the heating wire beyond the room or area in which it
27. his product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California law requires this warning to be given to customers in the State of California For more information www watts com prop65 Bostik Inc 11320 W Watertown Plank Road Wauwatosa WI 53226 1 800 726 7845 www bostik us com www bostikdiy com OM Bostik Wire 1229 EDP 81016319 Sostik Stronger Bonds Better Life Copyright 2012 Bostik
28. ing Use a 4 square box if installing three cables The box can be locat ed almost anywhere that is well ventilated However the best place is in the same room as the cable typically about 60 above the floor and within reach of the power lead wires of the cable If installing more than three cables it will be necessary to connect their power leads in a junction box first see Step 4 4 to keep from overfilling the control electrical box Then route one power supply from this junction box to the control box See Step 5 22 for special requirements if the control will connect to a heating cable entering a shower area STEP 4 3 Following code feed 14 or 12 gauge NM type electrical wiring from the circuit breaker panel to the control electrical box Leave about 6 8 of extra wire extended from the box to work with STEP 4 4 If the control box must be mounted in a location that is too far to reach with the power lead wires it will be necessary to mount a junction box where the lead wires can be terminated Use a standard junction box with a cover mounting it below the floor in the attic or in another easily accessible location It must remain easily accessible and not located behind a wall cabinet or similar obstruction Then use 14 or 12 gauge NM type or other accepted electrical wiring to connect from the junction box to the control box STEP 4 5 Drill two 1 2 holes in the baseplate directly below the control electrical box The
29. ings In some applications it can be used to heat the room as well but in gen eral it is not designed for this purpose heat loss calculations must be made to determine if enough heat will be provided to match the heat loss of the room STEP 1 1 Make a sketch of the room Measure the total square footage of floor area to be warmed measurements should be made all the way to the edge of walls cabinets tub etc for now Keep in mind the following e Heat will not radiate beyond about 1 1 2 on either side of the cable therefore consistent coverage is important The cables can be installed in permanent bench seats with tile or stone coverings Cables only with W on the nameplate label may be installed into shower floors and bench seats However do not install them into the walls Consider installing a dedicated cable in the shower area separate from the rest of the bath floor In case there is ever a problem with the shower instal lation this cable could be disconnected without loss of heat to the rest of the floor Acceptance of this shower application must be verified by the local inspector or authority having jurisdiction See Step 5 20 and Appendix 5 for details and precautions Do install cable within about 1 1 2 to 2 from a counter or vanity in the kick space to ensure warmth in this area Do not install the cables underneath cabinets or fixtures or inside a wall Excessive heat will build up and cause damage Do not
30. isting Construction STEP 6 8 Usea fish tape to pull the power leads up the wall to the control e e electrical box or junction box if one was used STEP 6 9 Secure the power lead fac tory splice into the chisled channel with hot glue see photo for Step 6 3 STEP 6 10 Below the control or wherever the floor sensor is to be 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 see photo Step 6 4 To make sure the sen sor tip does not create a high spot in the floor chisel a channel into the floor and lay the sensor tip into the channel Hot glue the tip into place see photo Step 6 5 STEP 6 11 Use a fish tape to pull the sensor up the wall to the control electri cal box and finish by securing a steel nail plate over the power leads and sen sor wires to protect them against baseboard nails STEP 6 12 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 power leads with a brief description as to which area they supply power Use tape to label them Cable 1 Cable 2 or 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 record for any future needs
31. l practice Expansion Joints Do not install heating wire through an expansion joint Install heating wire right up to the joint if necessary but not through the joint CAUTION Never bang a trowel on the Heating Wire to remove excess mortar from the trowel This could damage the heating wire HeatStep Wire Installation Manual 15 Double plywood over frame floor Tile stone or laminate flooring Cementitious Underlayment SL 150 WebCrete 95 WebCrete 98 or Ultra Finish Heating cable Plywood Underlayment Grade Plywood Insulation per International Residential Code Chapter 11 Joist Tile stone or laminate flooring Bostik Thin set Heating cable Cement backerboard Cementitious Underlayment SL 150 WebCrete 95 WebCrete 98 or Ultra Finish Plywood subfloor Insulation per International Residential Code Chapter 11 Joist Tile stone or laminate flooring Bostik Thin set or SL 150 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 16 HeatStep Wire Installation Manual Appendix 2 Typical Electrical Wiring Diagrams 120 and 240 VAC Typical Electrical Wiring Diagram with HeatStep Control 120 240VAC Dedicated 120 or 240VAC 20 amp maximum circuit Grou
32. m normal heat loss framed floor construction Two zones 120 volts Bathroom Zone 1a 1 spool 3 spacing Bathroom shower Zone 1b 1 spool 3 spacing Bath Tub O Spool Termination Strap Zone 1a Floor Sensor Control Install cables IMPORTANT Example of Bostik Thin set or SL 150 self leveling mor at least 6 away tar bed where cable is installed in a shower area and enters over the from toilet rings curb See Step 5 20 for complete details and Cautions This application into a shower area must be verified by the local inspector or the author ity having jurisdiction Detail of Shower Curb Tile Thinset Mortar Shower Curb HeatStep Wire Notches in Shower Curb to avoid sharp bends in cable 24 HeatStep Wire Installation Manual Spool termination Strap Recreation Room high heat loss below grade basement slab One zone 240 volts 1 spool 160 sq ft 2 spacing 69 ft of strap or three 25 ft rolls 1 spool 160 sq ft Qe ii AA A Control L 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 Any troubleshooting work should be do
33. n as close to the floor surface as possible drill two horizontal holes intersecting the top holes STEP 4 6 If conduit is required by local electrical code cut a length of 1 2 to 3 4 electrical conduit to run from the control box down to the baseplate At the baseplate it may be necessary to chisel out more of the wood to make it easier to feed the wires up through the conduit STEP 4 7 Mark the circuit breaker in the panel which feeds the system with Floor warming bath or similar description Existing Construction OVERVIEW It is recommended that the system be installed on a separate dedicated circuit coming directly from the breaker panel In existing con struction however it may be difficult to do this depending on the location of wiring and the breaker panel Tapping off an existing circuit may be pos sible but only if there is enough load capacity to handle both the system and any additional loads that may be placed on the circuit Keep in mind that typical hair dryers can pull up to 10 amps 1200 watts of load Follow all NEC CEC and other local electrical code requirements when installing this system Work should be done with great care and with the power turned off to the circuit being worked on 8 HeatStep Wire Installation Manual STEP 4 10 STEP 4 12 STEP 4 8 Install a maximum 20 amp circuit breaker s into the breaker panel depending on the load of the
34. nd 120 240 VAC HeatStep Control Load 1 120 VAC or 240 VAC Heating Cable maximum 15 amps Sensor Wire no polarity 120 VAC or 240 VAC CAUTION Make sure 120 VAC is supplied to 120VAC cables and 240VAC is supplied to 240VAC cables Otherwise dangerous overheating and possible fire hazard can result Typical Electrical Wiring Diagram with HeatStep Control 120 240VAC Dedicated 120 or 240VAC 20 amp maximum circuit Ground 120 240 VAC HeatStep Control Black Black 120 VAC or 240 VAC White Line 2 White Sensor Wire Two or more120 VAC or no polarity 240 VAC Heating Cables maximum 15 amps NOTE Installation must be performed by a qualified licensed electrician in accordance with local building and electrical codes ANSI NFPA 70 NEC Article 424 and CEC Part 1 Section 62 where applicable HeatStep Wire Installation Manual 17 Typical Electrical Wiring Diagram with HeatStep Control and Relay s Dedicated 120VAC or 240 VAC 20 amp maximum circuit Ground C4 120 240 VAC HeatStep Control Line 1 Black Black _ D Sensor Wire Two or more120 VAC or 120 VAC or 240 VAC no polarity 240 VAC Heating Cables maximum 15 amps White Line 2 White Use size 18 to 24 gauge 2 conductor shielded wire up to 100 feet 30m in length to connect HeatStep Control to HeatStep Relay Ground 120 240 VAC HeatStep Relay Line 1 Black Black Two or more120 VAC or 120 VAC or
35. ne with the power removed from the circuit unless otherwise indicated Call Bostik at 1 800 726 7845 for further assistance Problem Cable resistance measure ment is outside the range printed on the nameplate label Floor does not get warm Floor heats continuously Control is not working correctly Control is not working at all GFCI conflicts and false trips Possible Cause An analog ohmmeter using a moving needle was used to take the reading 25 HeatStep Wire Installation Manual Solution Obtain a digital ohmmeter able to read 0 to 20 000 ohms and remeasure the resistance If measurement shows an open or short circuit the cable has been damaged Record resistances between all wires and contact the manu facturer 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 atime The multi meter may be set to the wrong scale Cable has been damaged The ohmmeter should typically be set to the 200 200Q scale For heating wires with resistance range higher than 200 ohms on the nameplate label set the meter to the 2000 ohm 2kQ scale Measure cable resist
36. nsulated before applying the cables if at all possible See Phase 9 Install Insulation as well as the cross sections in Appendix 1 Controls The HeatStep controls will provide direct floor warming control for better comfort Other controls are not approved for use with HeatStep Cables Mortars Self leveling mortars are becoming more popular to use because of their ease of application over the cables If laying tile another layer of thin set will need to be applied in order to lay the tile Always use polymer modified cement based mortar Do not use solvent based adhesives or pre mixes because they are not as heat resistant Wire Fault Detector The Wire Fault Detector sounds an alarm if dam age occurs to the cable during installation The Detector stays connected to the power leads throughout cable and tile installation A small screwdriver for connecting the leads is included with the Wire fault detector Items Needed Materials HeatStep system HeatStep Wire Strap provided with cable Thermostat control with floor sensor 20 amp circuit breaker single for 120 VAC and dual for 240 VAC systems Electrical box extra deep for the control single gang not a gangable type or 4 square deep box with a single gang mud ring cover 4 junction box with a cover if needed Cable clamps for junction box for new construction Flexible or rigid conduit for new construction 12 gauge or 14 gauge electrical wiring cable
37. ntrol Use a 4 square deep box with a single gang mud ring cover if connecting three cables because the extra room is needed for the wire wire nuts and control HeatStep Wire Installation Manual 7 Phase 4 Electrical Rough in See wiring diagrams in Appendix 2 for different voltages and applications For additional help contact Bostik at 1 800 726 7845 New Construction see below for existing construction OVERVIEW We recommend the floor warming system be installed on a dedicated circuit coming directly from the circuit breaker panel Follow all National Electric Code NEC Canadian Electrical Code CEC and other local electrical code requirements when installing this system Work should be done with great care and with the power turned off to the circuit being worked on STEP 4 1 Install a maximum 20 amp circuit breaker s into the breaker panel depending on the load of the system Use a 120 VAC single pole breaker for a 120 VAC system Use a 240 VAC double pole breaker for a 240 VAC system For systems that are too large to directly power through one control but must be operated by one floor sensing control use a HeatStep control in combination with up to 10 HeatStep Relay Controls Contact a HeatStep dealer or the factory for more information STEP 4 2 Install an electrical box for the control If installing one to two cables use an extra deep single gang box to allow plenty of room for the wir
38. ntrol the instructions that came with the control or the wiring diagrams in Appendix 2 Defective control If a programmable control the programming may be incorrect Return control to dealer for replacement Carefully read and follow control programming instructions Incorrect voltage supplied or mismatched components used Test voltage verify parts See Incorrect voltage supplied above Floor sensor is not wired properly or is not working properly Make sure only one floor sensor is connected to the 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 No power is supplied Return control to dealer for replacement Check circuit breaker Measure voltage at the control Check all connections between breaker and control Floor sensor is not wired properly or is not working properly Make sure only one floor sensor is connected to the control Defective control An electric motor or a ballasted light source is sharing the circuit with the cable s Return control to dealer for replacement 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 CALIFORNIA PROPOSITION 65 WARNING WARNING T
39. r plywood sheeting is used to strength en the floor or if the heating wire will be placed directly onto the slab install heating wire in the thin set mortar bond coat above these materials b If a 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 leveling Mortar Applications These are appropriate applications if installing engineered wood vinyl laminate or carpet floor coverings Attach the heating wire to the subfloor or slab then pour self leveling mortar 3 8 to 1 2 Install floor covering after the mortar has cured Special Precautions Isolation Membrane Install the heating wire above the membrane whenever possible unless recommended oth erwise by the membrane manufacturer Insulation Insulation dramatically enhances the perfor mance 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 typica
40. rlayment float ing wood or laminate flooring carpet etc The combined R values of all floor coverings over the heating wire should not exceed R 3 Higher R values will diminish performance Consult the floor covering manufacturer to verify com patibility with radiant electric heat Also 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 heating 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 attaching hardwood Any air gap between the heating wire and the finished floor covering will drastically reduce the overall output of the heated floor HeatStep Wire Installation Manual 13 STEP 7 3 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 not use rubber backed prod ucts When placing furniture make sure an air clear ance 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 STEP 8 3 After floor coverings have been installed take resistance readings of the cable again to make sure it has not been inadvertently damag
41. run the cables into small closets or other confined areas where excessive heat will build up Do not install the cables closer than 6 from toilet rings to avoid possible melting of wax rings Do not cross expansion joints Install the heating wires 4 to 6 away from the perimeter walls of the room This will help avoid locating heating wire underneath finish trim STEP 1 2 Select the cable spacing Below are typical spacings for various types of rooms This spacing can vary depending on the insulation of the floor and room and the desired effect Never space cables closer than 2 apart this will cause a very hot area and may cause damage Typical uses e 2 spacing Sunroom floors basement slabs and baths with exterior walls NOTE Insulation is always recommended due to high heat losses in these areas Performance is never guaranteed due to construction and climate differences in these applications e 2 1 2 spacing Bathrooms kitchens living areas and basements e 3 spacing Hallways entryways and large areas with low heat loss STEP 1 3 Multiply the square footage measured in Step 1 1 by 0 90 to allow for 3 spacing around the edges of the floor area Use this resulting square footage to select the appropriate cable from the tables on page 4 Remember Do not place over 15 amps at 120 VAC 1800 watts or 15 amps 3600 watts at 240 VAC through a control e Select either 120 VAC or 240 VAC depending on
42. set to the 200Q or 2000Q 2kQ range to measure the resistance between the black and white wires of the cable power leads or black and blue wires for 240 VAC 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 Ground Lead White or Blue Lead Black wire to COM Red wire to Q 4 200 ohm setting Measure the resistance between either of the white or black leads and ground lead This measurement should be open usually indicated by an OL or a l This is the same as displayed when the test leads are not touch ing anything White or Blue Lead Baklei If there is any change in the reading record this information and contact lack Lea the factory before continuing This could indicate damage test lead prob lems 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 kQ range Measure between the lead wires of the HeatStep Control sensor This resistance varies according to the temperature sensed Table 3 provides approximate resistance to temperature values for reference Ground Lead White oy Blue Lead
43. the power available DO NOT mix voltages on the same system if more than one cable is to be installed to cover an area Load no more than 12 amps 1440 watts on a 15 amp circuit breaker or 16 amps 1920 watts on a 20 amp circuit breaker If you have an area that requires more than 15 amps of cables to be controlled by one thermostat use HeatStep Relay s to take the additional amp load See the Wiring Diagrams in Appendix 2 for help If the exact size of cable calculated is not found in the spool selection tables on page 4 it may be necessary to adjust the warming area s or select the next smaller spool size Remember the cable must never be cut shorter to fit and must be embedded completely in mortar in the floor Be care ful not to select a spool that is too large STEP 1 4 Use the wire strap included in wire kit to secure the cable to the floor One box contains 25 ft of strap enough to prepare about 50 sq ft of floor at 4 ft spacing Strap is usually spaced every 3 to 4 ft Use of methods to secure the cable other than those described in this Manual voids the Warranty and are not allowed unless authorized by the manufacturer in writing Do not use nails staples or similar 4 _ HeatStep Wire Installation Manual Table 1 Cable Sizes 240 VAC Spools Total Sq ft Total Sq ft Total Sq ft Wire Example There are Model 2 Spacing 2 1 2 Spacing 3 Spacing Length Amperage Resistance 270 sq
44. tts 10 W sqft 34 Btu h sqft when spaced 3 inches on center up to 15 W sqft 51 Btu h sqft when spaced 2 inches on center see Table 1 Maximum heater current 10 amps Maximum circuit load 15 amps Maximum circuit protection 20 amps breaker GFCI Ground Fault Circuit Interrupter required for each circuit included in the HeatStep 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 X see UL Label on product For indoor floor heating application only Shower area Listed see Step 5 20 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 Maximum exposure temperature continuous and storage 194 F 90 C Minimum installation temperature 50 F 10 C 2 spacing NEVER use less than 2 spacing 3 spacing NEVER exceed 3 spacing Kitchen Design 1 Heated area total area built in areas 2 Multiply heated area x 0 90 3 Select Appropriate product size Refrigerator HeatStep Wire Installation Manual 3 Phase 1 Design the System HeatStep Wire should be installed in all interior floor areas that are to be warmed It cannot be used for exterior applications snow melting or in ceil
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