INSTALLATION MANUAL
Contents
1. STEP 8 2 Select Type of Construction Choose the best thin set thick set or self leveling mortar method for the application See Appendix 1 regarding final floor installation techniques Consult with building pro fessionals and or the factory if assistance is required STEP 8 3 Take Another Resistance Reading After floor coverings have been installed take resistance readings of the cable again to make sure it has not been inadvertently damaged This is very important to do Record these readings in the Cable and Sensor Resistance Log page 6 Phase 9 Install Insulation Insulate under the subfloor for better performance and efficiency of the system Refer to the Appendix 1 for diagrams and insulation recommendations Phase 10 System Operation After all system components are in place and floor coverings installed briefly test the operation of the system but do not put the system into full operation until the mortar materials are fully cured typically one to four weeks See the mortar manufacturer s recommendations for the specific type of mortar used Many manufacturers of laminate and wood flooring recommend a maximum of about 84 F 29 C on the floor surface Be sure to program the control accordingly Consult the manufacturer regarding recom mended floor temperatures for the flooring being installed Energize the system Operate the controls so that the system turns on the floor warming cable The control will2. i Y D DI D A DEAR D MW oO Ne 2 OPL ANQ EE RD l AD rFAN L d INSTALLATION MANUAL 1 800 363 1501 Please leave this manual with the end user Ou 2 O comfort one installation Manual Welcome to Comfort One Wire Comfort One Wire is a simple economical way to warm any floor and provide years of lasting comfort This instruction manual provides complete details sugges tions 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 3 Specifications 4 Phase 2 Preparation 4 eic rM PE DEDIT 4 TIDSz cn csgeses star nine TREE IER U REA N EA RETE 5 Items Needed 5 Phase 3 Inspect the Cable and Sensor 5 Cable and Sensor Resistance Log 6 Phase 4 Electrical Rough in 7 New Construction 7 Existing Construction 7 Phase 5 Install the Cable 8 Getting Started 22e e oe eR EUER eee 8 Gen
3. 120 VAC or 240 VAC Heating Cable Sensor Wire no polarity TCRUTION 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 120 VAC or 240 VAC Typical Electrical Wiring Diagram with Comfort One Control 120 240VAC Dedicated 120 or 240VAC 20 amp maximum circuit Ground 120 240 VAC Comfort One Control Sensor Wire Two or more120 VAC or no polarity 240 VAC Heating Cables maximum 15 amps 120 VAC or 240 VAC 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 Part IX of the NEC ANSI NFPA70 and Section 62 of CEC Part 1 18 Q comfort amp one installation Manual Typical Electrical Wiring Diagram with Comfort One Control and Relay s Dedicated 120VAC or 240 VAC 20 amp maximum circuit Ground 120 240 VAC Comfort One Control Line 1 Black Black x 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 2 Conductor 18 to 24 AWG Signal Wire Ground E 120 240 VAC Comfort One Control Line 1 Black Black Two or more120 VAC or 120 VAC or 240 VAC 240 VAC Heating Cables White Line 2 maximum 15 amps White Diagram for connection of signal wire betwe
4. 10 21 26 CO240220 183 220 258 295 859 11 18 24 I Phase 2 Preparation N O e CAUTION NEVER bang a trowel or other tool on the heating cable ALWAYS Always completely embed the factory splice and all heating wire in mortar NEVER bend the splice or place any part of it in the wall or through the floor Lj Joop n NEVER use less than 2 5 spacing As with any electrical product care should be taken to guard against the potential risks of fire electric shock and injury to persons The following cautions must be observed NEVER cut the heating cable The 10 ft power lead may be cut shorter if necessary but never removed from the heating cable NEVER use nails staples or similar to fasten the heating cable to the floor NEVER bang a trowel or other tool on the cable Be careful not to nick cut or pinch the cable causing it to be damaged NEVER install the cables under cabinets or other built ins Excessive heat will build up under these items and cause damage NEVER install the cable in any walls over walls or partitions that extend to the ceiling or in closets NEVER extend the heating portion of the cable beyond the room or area in which it originates NEVER attempt to repair a damaged cable Contact the factory for assis tance NEVER overlap heating cables Dangerous overheating can occur NEVER allow a power lead or sensor wire to cross a heating cable dam age could r
5. 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 120V cables have black and white leads 240V cables have black and blue leads Concrete slab floor Surface temperatures rise slowly in a slab If after 5 to 8 hours of heating the floor is not warmer to the touch check for cable dam age 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 control the instructions that came with the control or the wiring diagrams in Appendix 2 Defective control Floor sensor is not wired properly or is located incorrectly f a programmable control the programming may be incorrect Return control to dealer for replacement Make sure only one floor sensor is connected to the c
6. 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 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 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 a power lead at a junction box feed 14 or 12 gauge electrical wire from this box to the control box tp 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 Kitc
7. use Comfort One 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 careful not to select a spool that is too large STEP 1 4 Select enough strap supplied by Comfort One 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 gt comfortfyone installation Manual Table 1 120 VAC Spools Total sq ft Total sq ft Total sq ft Total sq ft Model 2 5 Spacing 3 Spacing 3 5 Spacing 4 Spacing Length Amp Resistance Number 14 4 watts sq ft 12 watts sq ft 10 3 watts sq ft 9 watts sq ft ft Draw ohms Example 1 There CO120015 12 15 17 20 58 1 5 89 110 are 45 sq ft of CO120020 17 20 23 27 78 2 64 79 bathroom area to CO120025 21 25 29 33 97 2 5 49 61 be
8. 1 Controls The Comfort One controls will provide direct floor warming control for better comfort Other controls may not give the same desired STEP 3 2 Model FHC 032 0702 02 Serial 999999 Date Mfr 10 01 10 Resistance Range Ohms 24 30 2160W 240VAC 12Wisqft 3in 60Hz 180sqft 3in See Installation Instructions Voir les instructions sur l installation level of control Always select controls that will meet the voltage and amperage ratings of the system and are designed for resistance heating systems 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 LoudMouth sold separately The LoudMouth sounds an alarm if damage occurs to the cable during installation The LoudMouth stays connected to the power leads throughout cable and tile installation Items Needed Comfort One Wire Cable Strap and control all available from Comfort One Other items may be obtained at a local hardware store Materials Comfort One Wire system Cable Strap Comfort One 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 g
9. Installation Manual and any special written design or installation guidelines by Fasco Corp for this project e Provide proof that the Product was installed in accordance with the National Electrical Code NEC the Canadian Electrical Code CEC and all applicable local building and electrical codes EXCLUSIONS 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 investigate repair or replace the Product c Any labor or materials required to remove repair or replace flooring materials and other building materials such as cabinets trim and fixtures d Any freight or delivery costs related to the Product the control or any related flooring or electrical products Fasco Corp assumes no responsibility under this warranty for any damage to the Product caused by any tradespeople visitors on the job site or damage caused as a result of post installation work The staff at Fasco Corp is available to answer any questions regarding the proper installation or application of the Product at this toll free phone number 800 363 1501 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 FASCO CORP DISCLAIMS ANY WARRANTY NOT PROVIDED HEREIN INCLUDING ANY IMPLIED WARRAN
10. Junction Box Illustration showing how to connect three cables at the control electrical box L ih a S 3 a D a z o S T D pes D o S P gt 2 MY v1 10 ZL 21989 WN PJepuejs o Il G L1L2 G L1L2 Power Lead Power Lead Power Lead 120 VAC Wiring Legend Power Lead 240 VAC Wiring Legend G Green EEE L1 White DO L2 Black SE G Green E L1 Blue DT L2 Black SE T4 IG L1L2 G DAA In L1 L2 G L1 L2 Power Lead Power Lead 120 VAC Wiring Legend Power Lead Lead Power Power Lead 240 VAC Wiring Legend G Green EE L1 White 7 L2 Black SE G Green D L1 Blue J L2 Black SE Illustration showing how to connect multiple cables from multiple junction boxes at one control electrical box 20 O comfort one installation Manual Appendix 4 Connecting the LoudMouth Monitor 120 VAC Wiring Legend G Ground L1 White LoudMouth L2 Black DE LoudMouth 240 VAC Wiring Legend G Ground L1 Blue L2 Black RE Use minimum 18 gauge wire to make short jumper wires Illustrations showing left how to connect the LoudMouth monitor to two cables and right how to connect the LoudMouth to three cables The LoudMouth can monitor no more than three cables simultaneously Do NOT leave the power leads
11. box can be located 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 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 Then 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
12. breaker panel Please be aware that local codes may require this product and or the thermostatic control be installed or con nected 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 subfloor 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 7 C 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 15 F 9 5 C 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 10 15 F 9 5 to 12 C 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 9 Install Insulation on page 13 Comfort One Wire is a complete heating cable consisting of a series resistance heating cable and single power lead for easy single point connection The he
13. ft roll Spool termination Strap gt 7 X r3 Shower E o Control Floor 1 spool Sensor 100 sq ft 3 spacing Install cables at least 4 6 away from toilet rings ea l Bath Tub Floor Sensor 4 Le 1 spool 80 sq ft 3 spacing Closet Ce Dual Vanity Ce B Control Floor Master Bathroom Sensor 1 l normal heat loss framed floor construction gosa tt nis zone 120 volts 1 spool 90 sq ft 5 IEEE S 3 spacing 3 spacing 49 ft of strap or two Es 2 9 25 ft rolls Q CY Strap Ww Shower O J U O Closet Toilet 7 Install cables Spool at least 4 6 away termination from toilet rings Bath Tub o Q comfort amp one installation Manual 23 Basement Bathroom high heat loss below grade basement slab One zone 120 volts 1 spool 60 sq ft 3 spacing 39 ft of strap or two 25 ft rolls 1 spool 60 sq ft 3 spacing Vanity Closet o Control bw Floor Vanity Sensor t Spool termination Strap Shower Oo Bath Tub Master Bathroom normal heat loss fr
14. membrane be installed directly to the slab or the self S leveling mortar layer underneath the tile This flexible layer reduces the EN chance of minor stress and fractur k ing in the slab from being transmit ted upward to the tile Reinforcement To further strengthen the floor consider laying a 1 1 4 to 2 mudbed reinforced with metal or plastic lath directly onto the optional antifracture mem Self leveling mortar over slab on grade brane Then install the cable s Latex Portland cement mortar bond coat Heating cable Antifracture membrane or cork underlayment as needed Slab Latex Portland cement mor tar bond coat Heating cable Mortar bed Antifracture membrane or cork underlayment as needed Slab Insulation beneath slab per International Residential Code Chapter 11 Framed Floor r 3 m Tile stone or laminate flooring Construction and Applications In framed floor construction the two primary concerns are insulation and floor rigidity Without proper insulation radiant heat leaks into the joist spaces And unless the ply wood subfloor is properly reinforced stresses in the subflooring can cause unsightly cracking in the tile floor insulation The use of insula unon eee per International Residential tion in the joist spaces dramatically Code Chapter 11 enhances the performance and effi ciency of the floor warming system Insulation with an R value o
15. not be returned This includes cable that has had mortar or concrete materials applied to it These materials cannot be repaired and cannot be resold therefore we cannot accept them Fasco Corp 165 Rue Deslauriers St Laurent Qu bec H4N 284 800 363 1501 IOM CO Wire EN 1117 Effective 05 01 2011
16. warmed with 120 CO120030 25 30 35 40 117 3 37 46 VAC The cable is to C0120035 29 35 41 47 136 3 5 33 41 be spaced at 3 to CO120040 33 40 47 54 156 4 27 35 provide 12 watts CO120045 37 45 52 60 175 45 24 30 afe providing CO120050 41 50 58 67 195 5 21 26 CO120060 50 60 70 80 234 6 20 26 comfortable warmth CO120070 58 70 82 94 273 7 16 21 across the floor area CG120080 66 80 94 107 312 8 13 18 As seen in Table 1 CO120090 75 90 105 121 351 9 12 15 use Model Number CO120100 83 100 117 134 390 10 10 13 CO120045 CO120110 91 110 129 148 429 11 9 12 Example 2 There Table 2 240 VAC Spools i dm sanis CO240010 8 10 12 13 39 0 5 524 624 CO240020 17 20 23 27 78 1 254 311 area to be warmed CO240030 25 30 35 40 117 15 181 222 with 240 VAC The CO240040 33 40 47 54 156 2 128 157 cable is to be spaced CO240050 41 50 58 67 195 25 98 122 at 4 to provide 9 CO240060 50 60 70 80 234 3 74 91 watts sq ft provid CO240070 58 70 82 94 273 3 5 66 82 ing warmth across CO240080 66 80 94 107 312 4 55 69 the entire floor area CO240090 75 90 105 121 351 45 48 59 As seen in Table CO240100 83 100 117 134 390 5 41 52 2 choose Model CO240120 100 120 140 161 468 6 40 51 Numbers CO240120 CO240140 116 140 164 188 546 7 33 41 and CO240140 to CO240160 133 160 187 215 624 8 27 35 end up with about CO240180 149 180 210 241 702 9 24 30 349 sq ft covered CO240200 166 200 234 269 781
17. TY OF THE MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE FASCO CORP FURTHER DISCLAIMS 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 FASCO CORP 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 FASCO CORP MAKES NO REPRESENTATION THAT THE FLOOR TEMPERATURE WILL ACHIEVE ANY PARTICULAR TEMPERATURE OR TEMPERATURE RISE UL STANDARD LISTING REQUIREMENTS LIMIT THE HEAT OUTPUT OF Comfort One CABLES AND AS SUCH USERS MAY OR MAY NOT BE SATISFIED WITH THE FLOOR WARMTH THAT IS PRODUCED FASCO CORP DOES WARRANT THAT ALL CABLES WILL PRODUCE THE RATED OUTPUT LISTED ON THE CABLE NAMEPLATE WHEN OPERATED AT THE RATED VOLTAGE Some provinces do not allow the exclusion or limitation of incidental or consequential damages and some provinces 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 province to province TERMS AND CONDITIONS Shipping Discrepancies Incoming material
18. Warranty Fasco Corp the Company warrants Comfort One electric floor warming cable the Product to be free from defects in materials and workmanship for twenty five 25 years from the date of manufacture Thermostats and controls sold by Fasco Corp are warranted parts and materials for one 1 year Refer to the warranty provided with the control for specific information This warranty is transferable to subsequent owners Under this Limited Warranty Fasco Corp will provide the following remedy If the Product is determined by Fasco Corp to be defective in materials and workmanship and has not been damaged as a result of abuse misapplication or modification the Company will refund the cost of the original Comfort One cable multiplied by the percentage of the warranty period remaining As an example a 100 cable that is 5 years old at the time of defect would receive 80 which is 20 25ths of the original cost of the Product In order to make a claim you must a Contact the Company with details relating to the nature of the defect the installation and history of operation of the Product b At the Company s discretion and at the owner s expense ship the Product or defective portion of the Product to the Company or the Company s local representative or distributor for evaluation c Provide a retail sales receipt or proof of purchase for the Product d Provide proof that the Product was installed in accordance with the Comfort One
19. amed floor construction One zone 120 volts 1 spool 20 sq ft 3 spacing 11 ft of strap or one 25 ft roll Install cables Spool at least 4 6 away termination from toilet rings A L x6 Toilet Closet Bath Tub 1 spool 20 sq ft 3 spacing Strap Floor Control Sensor 24 gt comfortfyone installation Manual Recreation Room high heat loss below grade basement slab One zone 240 volts 1 spool 160 sq ft 3 spacing 69 ft of strap or three 25 ft rolls 1 spool 160 sq ft 3 spacing AL Control L 1 4 Floor Sensor spool LN s termination i Strap Q comfort amp one installation Manual 25 Master Bathroom normal heat loss framed floor construction Two zones 120 volts Bathroom Zone 1a 1 spool 60 sq ft 3 spacing Bathroom shower Zone 1b 1 spool 20 sq ft 3 spacing Shower ili Zone 1b Bath Tub Q Spool O Termination UU l Shower Curb _ Strap Zone 1a Floor n Sensor O wm Co IMPORTANT Cable is installed underneath the waterproof membrane and enters over the curb See Step 5 22 for complete details and Cautions This application into a shower area must be verified by the local inspector or the authority having jurisdiction O comfort One installation Manual Comfort One Limited 25 year
20. ang 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 consult local code Wire nuts if using a junction box Nail plate Polymer modified cement based mortar Tools Digital multi meter for ohms testing must read up to 20 000 ohms O to measure sensor Drill with 1 2 bit Hammer and chisel Wire strippers Phillips screwdriver Fish tape for existing construction Hole saw for existing construction Trowel 81007407 plastic preferred with 3 8 notches or greater Phase 3 Inspect the Cable and Sensor STEP 3 1 Take the cable out of the box and inspect it to make sure there is no visible damage There are shielded leads coming out of the spool of cable called the power leads they are simply power supply cables that do not heat The power leads are approximately 10 ft long and will connect the heating cable to the control for power 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 page 6 If installing more than one cable do this for each of them 6 gt comfortfyone installati
21. ape 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 Phase 7 Install the Control STEP 7 1 Read and follow the instructions that come with the Comfort One controls STEP 7 2 Refer to the wiring diagrams in this manual for different volt ages 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 warm ing 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 installa tion very carefully for evidence of damage or missing sensor s STEP 7 4
22. as used to take the reading 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 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 When connecting more than one cable to the control multiple cables must be wired in parallel i e black to black white to white The ohmmeter may be set to the wrong scale For instance the 200 K ohms scale measures up to 200 000 ohms Cable has been damaged The ohmmeter should typically be set to the 200 ohms scale with the exception of cables having a rating above 200 ohms on their nameplate label If the resistance reading is outside the range printed on the nameplate label contact the manufacturer 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
23. ating cable cannot be cut to fit Voltages 120 240 VAC 1 phase Watts 9 W sqft 31 Btu h sqft when spaced 4 inches on center up to 14 4 W sqft 49 Btu h sqft when spaced 2 5 inches on center see Table 1 Maximum heater current 11 amps Maximum circuit load 16 amps Maximum circuit protection 20 amps breaker GFCI Ground Fault Circuit Protection required for each circuit included in the Comfort One control Listing UL Listed for U S and Canada under UL 1673 and CAN CSA C22 2 No 130 03 File No E185866 Application X see UL Label on product For indoor floor heating application only Embedded in polymer modified cement based mortar 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 STEP 1 1 3 spacing NEVER use less than 2 5 spacing 4 spacing NEVER exceed 4 spacing Q comfort amp one Installation Manual 3 Phase 1 Design the System Comfort One 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 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 Mak
24. connected in series like this when making final wiring connections the cables will not heat sufficiently Q comfort amp one installation Manual 21 Appendix 5 Sample Layouts Kitchen and Family Room normal heat loss slab on grade with insulation Two zones 240 volts Kitchen Zone 1a 1 spool 70 sq ft 3 spacing Kitchen Zone 1b 1 spool 120 sq ft 3 spacing Family Room Zone 2 1 spool 241 sq ft 4 spacing 190 ft of strap or eight 25 ft rolls St Spool termination 1 spool aP 120 sq ft H 3 spacing Sink 9 gt e o 3 et Zone 1b R et o o v 3 Qa A v S E O O Island lt Zone 2 3 GO OO 6 a 2 Le 5 3 Zone 1a K N l 1 spool Zone 1 Zone 1 Zone 2 Zone 2 1 spool Spool 70 sq ft Sensor Control Control Sensor 241 sq ft termination 3 spacing 4 spacing Layouts continued on next page 22 gt comfortfyone installation Manual Master Bathroom normal heat loss framed floor construction One zone 120 volts 1 spool 100 sq ft 3 spacing 35 ft of strap or two 25 ft rolls e BathTub Install cables at least 4 6 away from toilet rings Strap Master Bathroom normal heat loss framed floor construction One zone 120 volts 1 spool 80 sq ft 3 spacing 24 ft of strap or one 25
25. d control Q comfort amp one installation Manual 7 Phase 4 Electrical Rough in See wiring diagrams in Appendix 2 for different voltages and applications For additional help call 800 363 1501 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 Use a Ground Fault Circuit Interrupter GFCI type if not using our controls which have a built in GFCI For systems that are too large to directly power through one control but must be operated by one floor sensing control use a Comfort One con trol in combination with up to 10 Comfort One Relay Controls Contact a Comfort One 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 wiring Use a 4 square box if installing three cables The
26. e 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 Heat will not radiate beyond about 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 Type W cables may be installed into shower floors and bench seats under the waterproofing system 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 installation 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 22 and Appendix 5 for details and precautions Do not install the cables underneath cabinets or fixtures or inside a wall Excessive heat will build up and cause damage Do not run the cables into small closets or other confined areas where excessive heat will build up 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 closer than 6 from toilet rings to avoid possible melting of wax rings In open areas like sunrooms or dining rooms consider
27. e 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 lengths 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 page 6 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 gt comfortfyone 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
28. e 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 side 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 heating cable STEP 5 26 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 Comfort One Control Factory Splice Thermostat Sensor Strap Thin Set Mortar Tile Stone Comfort One Wire installed in shower floors and or benches under the waterproofing system See Step 5 22 and Appendix 5 Final Steps STEP 5 27 f 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 to 4 ft intervals Spray th
29. e 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 for NEVER use less than 2 5 spacing assistance Depending on the shape of the area it may help to think of it in terms of several smaller areas gt comfortfyone Installation Manual 9 General Installation STEP 5 5 Measure about 3 from the wall for the strap If the design called for 6 12 away from the wall install the strap at that distance In counter or vanity kick spaces install the strap so the cable will be 1 1 2 to 2 away from the vanity STEP 5 6 Cut the strap to fit the length of the first area 24 STEP 5 7 Secure the strap to the floor using double sided tape if factory supplied with your cables or using hot glue STEP 5 8 For added securement on concrete floors use a hammer drill to set holes into the concrete Secure the strap every 6 10 by driving anchors into the holes STEP 5 9 Cut another piece of strap for the other end of the area and secure 3 from the wall s or other obstruction s STEP 5 10 Unreel the power leads of the cable up to the factory spl
30. e manufac Es s turer S r ead In place of an antifracture mem brane an uncoupling system can be installed to prevent deflection in the subfloor from affecting the tile surface Tile stone Latex Portland cement mortar bond coat Heating cable Backer board Plywood subfloor Insulation per International Residential Code Chapter 11 Joist Latex Portland cement mortar bond coat Heating cable Plywood Plywood subfloor Mortar Beds SA Insulation The cables can be installed in LE three types of mortar beds thin set or thick set mortar beds 3 8 to 1 thick and self leveling mortar beds 1 4 to 1 2 thick Thin set Mortar Beds If the cable Thick set cement mortar with lath will be placed directly onto the slab Cement mortar metal lath TCA 145 03 or if backer board or plywood rein forcement is used on a plywood sub Tile stone floor first install the cable then apply the thin set mortar bond coat directly Ec over the cable and lay the tile F z Thick set Mortar Beds If a thick er mortar bed is used to strengthen the floor the cable can be installed Mortar bed under either the mortar bed also Metal or plastic lath known as dry set or under the mor tar bond coat directly below the tile or stone In a thick set application the cable is generally installed above the mortar bed but before the thin set bond coat Thick mortar beds of this type requir
31. e the use of a reinforcing mesh or lath per International Residential Code Chapter 11 Joist Latex Portland cement mortar bond coat Heating cable Plywood subfloor Insulation per International Residential Code Chapter 11 Joist Q comfort amp one installation Manual 17 If plastic lath is used instead of the typical metal lath the cable can be installed before pouring the self level ing mortar bed CAUTION If metal lath is used in the mortar bed do not allow the cable to come in direct contact with the lath Damage to the cable could result Self leveling Mortar Beds Self leveling mortar beds are appropriate if installing non masonry floor cover ings such as engineered wood vinyl laminate or carpet Attach the cables to the slab or subfloor then pour a 1 4 1 2 thick layer of self leveling mortar over the cables according to manufacturer s specifications Install the floor coverings after the mortar has cured Regardless of the type of mortar bed used in any particular application always secure the cable to the floor first then cover it with the mortar or cement Never attempt to lay or work the cable into a previously poured layer of wet mortar Surface Coverings It is strongly recommended that tile and stone flooring be installed according to manufacturer s recommen dations Tile Council of North America TCNA guidelines and ANSI specifications Follow industry and manu facturer s r
32. eck for Short Circuits 55 F 13 C 17 000 ohms Measure resistance between the black and ground leads and between 65 F 18 C 13 000 ohms the white and ground leads blue and ground leads for 240 VAC cables and record this value below These measurements should be infinite ohms no continuity A cut or pinch in the wire is typically indicated by a 18 C 75 F 24 C 10 000 ohms 29 C resistance value less than the cable resistance range 85 F 29 C 8 000 ohms 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 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 Install an extra deep single gang box if connecting one or two cables to the control 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 an
33. ecommendations when installing non masonry floor coverings such as hardwood vinyl laminate or floating floors For best performance minimize the insulating value of the coverings selected Thicker carpets or pads will reduce the heat available on the surface and lose heat below A total R value for all surface materials of R 3 is the maximum recommended most underlayment wood and pad carpet combinations are acceptable Never exceed R 11 total Other Considerations Expansion joints In slab or mortar applications do not install the cables through an expansion joint unless an appropriate antifracture membrane is installed per TCA recommendations If not using an antifracture mem brane install the cables right up to the joint if necessary but not through the joint Mosaic tile When laying mosaic tile first embed the cables in the appropriate mortar bed as shown in the diagrams on the previous pages and allow to cure per manufacturer s instructions Then thin set the mosaic tile according to typical practice REMEMBER If in doubt about any aspect or phase of the installation consult with building professionals and or the manufacturer regarding specific installation details before beginning Appendix 2 Typical Electrical Wiring Diagrams 120 and 240 VAC Typical Electrical Wiring Diagram with Comfort One Control 120 240VAC Dedicated 120 or 240VAC 20 amp maximum circuit Ground 120 240 VAC Comfort One Control
34. en Comfort One Control and Relays 120 240 VAC 120 240 VAC 120 240 VAC Comfort One Control Comfort One Relay Comfort One Relay Up to 10 Comfort One Relays can be connected to one Comfort One Control 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 Part IX of the NEC ANSI NFPA70 and Section 62 of CEC Part 1 Q comfort amp one installation Manual 19 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 Thermostatic Control 4 x 4 Electrical Box Thermostatic Control 4 x 4 Electrical Box 120 VAC Wiring Legend 240 VAC Wiring Legend G Ground Em L1 White L 1 L2 Black DS G Ground L1 Blue 1 L2 Black MENEEEEEEND NM Cable 120 VAC Wiring Legend L1 White 3 G Copper L2 Black DS Il M Bie N S eo Li JL NM Cable 240 VAC Wiring Legend L1 Red Co G Copper E L2 Black NENEEEEEEN 4 x 4 Junction Box 4 x 4
35. eral Installation 9 Other Installations 10 Final Steps 2o rete pv rv REATUS hae ne 11 Phase 6 Finish Wiring 12 New Construction 12 Existing Construction 12 Phase 7 Install the Control 13 Phase 8 Install the Floor Coverings 13 Phase 9 Install Insulation 13 Phase 10 System Operation 13 Troubleshooting Guide 14 Appendix 1 Types of Construction 15 Appendix 2 Typical Electrical Wiring Diagrams 17 Appendix 3 Connecting Multiple Cables 19 Appendix 4 Connecting the LoudMouth 20 Appendix 5 Sample Layouts 21 Specifications Installation Facts Time to install An average size bathroom should take about two hours to install the cables and about four hours to install the electrical box control and power supply Skill level Intermediate skills in electrical wiring and laying floor coverings required Normally the heating product may be secured in place by qualified installers However consider hiring an electrician to rough in the wiring espe cially if it is necessary to route from the circuit
36. esult NEVER embed the cables in adhesives intended for laminate or vinyl flooring Cables must be completely embedded in cement based polymer modified mortar NEVER apply the wrong voltage to a cable Damage can result NEVER use less than 2 5 spacing ALWAYS completely embed the heating wire and factory splice in mortar ALWAYS maintain a minimum of 2 5 spacing between cables ALWAYS use copper only as supply conductors to the control and the cable Do not use aluminum ALWAYS test the cable resistances and record them in the Cable and Q comfort amp one Installation Manual 5 ALWAYS Sensor Resistance Log page 6 ALWAYS pay close attention to voltage and amperage requirements of the circuit breaker control and the cable system For instance do not supply 240 VAC to 120 VAC controls and cables ALWAYS make sure all electrical work is done in accordance with local building codes the National Electrical Code NEC especially Article 424 Part IX and Section 62 of the Canadian Electrical Code CEC Part I 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 insulated before applying the cables if at all possible See Phase 9 Install Insulation as well as the cross sections in Appendix
37. f 19 will Latex Portland cement mortar bond coat Heating cable Self leveling mortar bed Antifracture membrane or cork underlayment as needed Concrete slab with rewire or rebar 16 O comfort one installation Manual be sufficient for most regions while in more temperate areas R 11 will suffice Do not install rigid insulation lay ers directly above or below backer board or mortar If possible install Construction and Applications insulation as shown in the diagrams at right Reinforcement There are several Thin set mortar over framed floor options for strengthening the sub Dry set or latex cement mortar TCA F 144 03 floor 1 Add 3 4 thick plywood on top of the existing subfloor 2 Pour a 1 4 1 2 thick layer of self leveling mortar over the existing subfloor then install the cables on top of the mortar layer 3 Install a quality cementitious Mortar bed backer board or fiber cement under layment over the subfloor Then install the cable and lay the tile Antifracture membrane While optional it is recommended that an antifracture membrane be installed to reduce the chance of minor stress and fracturing in the subflooring from being transmitted upward to Thin set mortar over framed floor the tile If an antifracture membrane Dry set or latex cement mortar TCA RH130 03 is used install the cable above the membrane unless otherwise recom Tile stone mended by the membran
38. h a non masonry wall or curb causing it to overheat 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 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 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 adhesives Do not use fasteners that penetrate any water proofing membrane or waterproofing system Fill in the floor area with Q comfort amp one installation Manual 11 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 th
39. hen Bath or similar This will make it easier to identify the leads later on Take photos of the installation This will provide a use ful record for any future needs Existing Construction STEP 6 8 Use a fish tape to pull the power leads up the wall to the con trol electrical box or junction box if one was used STEP 6 9 Secure the power lead factory splice into the chisled chan nel 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 Q comfort amp one installation Manual 13 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 t
40. ice 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 11 Before installing more strap fill in the first section with cable Begin by making a strain relief at the beginning so the cable is not acci dentally pulled loose nd STEP 5 12 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 NEVER space the cables less than 2 5 apart ls STEP 5 13 If there are additional areas to cover with cable cut the lengths of strap necessary attach them to the floor and begin weaving ZOOM the cable into that area Qi 10 gt comfort amp one installation Manual STEP 5 18 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 14 For an angled area such as a corner shower first cut
41. installing the cables 6 to 12 away from the perimeter of the room since people rarely stand this close to walls 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 5 apart this will cause a very hot area and may cause damage Typical uses 2 5 spacing Bathrooms kitchens living areas and sunroom floors 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 3 5 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 Select either 120 VAC or 240 VAC depending on 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 con trolled by one thermostat
42. lse trip Run a dedicated circuit to the floor warming system Q comfort amp one installation Manual 15 Appendix 1 Types of Construction and Applications The cross sections on these pages depict types of construction slab vs frame floor and applica tions commonly used in the instal Construction and Applications lation of the cable Choose the best installation detail for the particular construction and application Thin set mortar over slab Dry set or latex cement on slab TCA RH115 03 Slab Construction and Applications Insulation In new slab construc tion it is highly recommended that foam insulation be installed under and around the slab to prevent loss of radiant heat into the surrounding soil In existing construction where insulation under the slab is absent itis strongly recommended that a layer of insulating material be attached to the slab prior to the Insulation beneath slab installation of the cable per International Residential Code Chapter 11 Cork for example possesses a minimal R value that will help keep the radiant heat at the floor surface Thick set mortar bed over slab Consult the cork manufacturer Cement mortar bonded TCA F112 03 regarding proper application and attachment of the cork to the con i crete slab There are other options es Tile stone or laminate flooring for insulation as well i Antifracture membrane While optional it is recommended that an antifracture
43. normally indicate that power is being supplied to the cable It will take some time for the cable to warm up Using a clamp type ammeter electricians normally carry these pull the control out of the wall and determine whether the cables are pulling current thus indicating they are working as intended Turn the system off after NO MORE than 10 minutes of operation Do not operate the system again until the floor mortar is cured Once the flooring is completely cured the control can be used to operate the sys tem for many years to come v A 14 O comfort one installation Manual 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 done with the power removed from the circuit unless otherwise indicated Call 800 363 1501 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 Floor temperature shows HI or may show tempera ture over 100 F 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 w
44. nother 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 ST 12 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 itself Do not space heating cables less than 2 5 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 th
45. of 1 2 to 3 4 electrical conduit to run from the control box down to the base plate 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 gt comfortfyone installation Manual STEP 4 8 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 Use a Ground Fault Circuit Interrupter GFCI type if not using one of our controls which have a built in GFCI For system
46. on Manual IMPORTANT To retain the Limited Warranty the following measure ments must be recorded and all steps of this manual followed STEP 3 3 Take resistance readings of the cable and floor sensor to make sure they are not damaged It is very important that this be done throughout the entire installation process Use a quality digital ohm meter or multimeter able to measure up to 20 000 ohms Q to make these measurements Analog meters that use a moving needle are not accurate for this product and should not be used Take resistance readings 1 before beginning the installation 2 after the cable and sensor are fastened to the floor and 3 after floor coverings are installed Checking these measurements frequently during finished floor installation is strongly recommended in order to avoid burying a damaged cable Check for Breaks Measure resistance between the black and white cable leads black and blue leads for 240 VAC cables and record this in the chart below This measurement should be within the cable resistance range shown on the nameplate label Measure between the lead wires of the floor sensor This resistance varies according to the temperature sensed in the tip The sen sor resistance table at left provides approximate values for comparison A cut or break in the wire is indicated by a resistance of infinite ohms no Floor Sensor Resistance Values continuity Temperature Typical Values Ch
47. ontrol Also see Sensor is loose or broken above Carefully read and follow control programming instructions ncorrect 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 Also see Sensor is loose or broken above 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 Also see Sensor is loose or broken above Defective control More than one GFCI on the circuit Return control to dealer for replacement GFCI units sometimes trip when there is nothing wrong with the equipment on the circuit but when there is more than one GFCI Reroute power to avoid having more than one GFCI on the circuit An electric motor or a ballasted light source is sharing the circuit with the cable s Electric motors and other electrical devices can cause a GFCI to fa
48. s should be inventoried for completeness and for possible shipping damage Any visible damages or shortages must be noted prior to accepting the material Once the receiving personnel accepts 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 Fasco Corp or the Company s local representative or distributor within 15 days of the shipping date entered on the packing slip for the order Return Policy Comfort One items may be returned if they are not damaged or used There will be a 25 restock charge applied to items returned due to overstock or customer order error All returned items must be undamaged and unmodified and must be in new condition Comfort One Product controls or other parts that have a quality defect will be replaced not credited at no charge to the customer according to the conditions of this Limited Warranty If an item is shipped as a result of error by Fasco Corp or their distributor there will be no restocking charge All items returned for either 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 180 days from date of purchase are excluded from these terms and conditions and may not be returned Products that have been damaged or heating cable s that have been cut may
49. s that are too large to directly power through one Comfort One control but must be operated by one floor sensing control use a Comfort One Control in combination with up to 10 Comfort One Relay Controls Contact a Comfort One dealer or the fac tory for more information 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 us three cables The box can be located almost anywhere that is well venti STEP 4 10 lated However the best place is in the same room as the cable typically M 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 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 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 a
50. several pieces of strap a little longer than the cable spacing being used STEP 5 15 Use a chalk line or pen to mark the floor at 3 from the edge of the shower STEP 5 16 Use this chalk line to STEP 5 17 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 17 Fill in the section with cable Door entryway STEP 5 18 For an entryway or other small area where warmth is required begin by cutting two lengths of strap a little shorter than the eng of the entry opening Then secure the two straps parallel to each other Bench Seat STEP 5 19 f 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 Cable must be embedded beneath the waterproof system and the entire heating cable including factory splices must be embedded in mortar The heating cable must not exit the shower area under or throug
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