Installation Manual - CBS Radiant Heating Systems
Contents
1. Installation Manual Safe t SLAB Heating Cables Storage Heating System www cbsheating com 1800 709 000 info cbsheating com CBS Heating Systems Safe t SLAB Installation Manual 1 CBS Safe t SLAB Thermal Storage Heating System The Safe t SLAB Thermal Storage Heating System consists of heating cables installed in the foundation of a building either in the concrete slab or in the sand bed below the concrete slab Control of the heating cables is achieved via the TRO310F thermostat A separate magnetic contactor and GFCI are required for current loads above 16A The principle of thermal storage heating consists of heating a concrete slab One of the economic benefits of Safe t SLAB is that it can make effective use of off peak electricity pricing The slab is thus charged with heat that gently radiates to the building above throughout the day providing a comfortable efficient and reliable heat source Benefits of the Safe t SLAB thermal storage are numerous over other heating methods and include Lower capital and operating costs Easy and flexible installation combined with a single point connection Reclaimed interior floor space no furnace boiler required Decorating freedom no heating registers to keep clear Silent safe and efficient operation No cold spots Energy efficiency Reduced dust and allergens Higher degree of comfort Versatile and easy to install the Safe t SLAB thermal storage system is the optimal w2. rm a m to C aoa tu ea TT L 1 C m dt E 19 JoyoeUuoy ui ual a je a age qe cd CBS Heating Systems Safe t SLAB Installation Manual APPENDIX A TYPICAL SAFE T SLAB WIRING DIAGRAM CONTINUED L I nl o NI gt FF o YI i P rm GO ny _ 4 rt Log C2 E e ct Tu D a ul CO C m II may 15 p am UU nm du Ow y _ mo n 030 m on rt Oo D i gus i A Vn lool auc pal Los JE LU JO unu TI T e eo EeipunoJD e JO uon iae e BO ouletg Jad pauinbal si Jo eq IU 10 palinbay j aap uoine oud 1n Je1s Ajuejod oN injejedule 100 O Bald pepLieLliooo MIB UOS S Jeu Bua Sa sdwy 9 S E SOWWJIOU ONISIM 3SvHd H33I3IHHL IVOIdAL a D D un rt T ws on 5 C i ep e Ea C E14 TI mE rL 0 bt a g Ca D Cn T D D D D C lt oS N da m 0 09 T fas 2 JT CO mt rf D Cy toa m p 4 A on lt VU mi gyme UC D Cc v e DE gt ri E D Ua Lno JE LI Sues Lo 1l g h aij JO l ap dI E J Ql MI 3 L jd 101261u02 DEO PEO PEO peolE Edq E J 0
3. Installation Manual APPENDIX A TYPICAL SAFE T SLAB WIRING DIAGRAM C1 r s ow S A P II n 1 CO C NINE 0 Cc n L3 3 f rt a LI Cu cT ue E CJ D X mM DI U i T tn Go 7 OLY 34S tro Ll O gt Ce N lt Q Z NI m _ o C CL gt D DSS 6 Q ow i y oa D DT a uw tt a O M a LI C2 e C1 pe LN w ry i Lil Lil Ww Ln Gn D x c pil Ti i rm m Lg yd rm dy M D x E m Ca e rt C7 Lag a t M TI iD Iz m n 2 ODO S tt D C C1 D a 41 rmt DI in AK 3 n A DI rt DU T sal E Q wc a t bod pum rm Oo C UN p 2 D I sao Ti Ca Lg Lg CO e x np Bel LU 1 oY eo 2 D morto j J no L m ru rt U T ul T n Ta LI JELU WIS SI a C i lt H QD t a tU r mp riu x Q U C3 I d as s d od MN sduuv 9 eISOWIOU ONISIM ASVHd d IONIS IVOIdAL v wc 2 ha 4 C 5 CO ho DI Ww Be a D E e J m e in D n CY DI D Dm TD D OIL T o lt lt 7 ci Ce n m Aoc Om D E CI cs 4 QU A C 1 t 0 1 I mM O oT ci mM z E B TEN C Sete NI s Al E i j AHI ILLILLII E
4. on the Cable Resistance Certificate TIP CBS recommends taking a picture of the cable layout and conduit placement during installation This can help in the unlikely case that the cable needs repairs and for warranty claims STEP 5 POUR THE CONCRETE SLAB Pouring the concrete slab Ensure that the contractors are careful not to damage the cable with tools heavy machinery etc Once the slab is poured but concrete is still wet measure the resistance once again as outlined in step 3 and record the information on the Cable Resistance Certificate It is not recommended to power the cables until the concrete has cured approximately 30 days Check with the concrete manufacturer for exact curing times Doing so can affect both the integrity of the slab and the subsequent proper operation of the Safe t SLAB cable STEP 6 CONNECTING POWER SUPPLY AND THERMOSTAT The connection of the TRO310F thermostat must be done by a qualified electrician familiar with heating cables and in accordance with Australian AS 3000 Wiring Regulations Remember to properly ground the heating cable braid If this is not already done the sensor should be installed in the conduit Remember that the sensor should reach the sealed end of the conduit Connect the thermostat and sensor according to the wiring diagram in appendix A A final resistance reading of the cables should be carried out as discussed in step 3 and the measured values recorded on the Cable Resistance Certif
5. ay to heat your residential commercial or industrial building CAUTION Safe t SLAB is a heating system usually intended to be the sole source of heat in the building 2 Safe t SLAB Cable Specifications Rated Volts Safe t SLAB Cables Output Safe t SLAB Cables Heating Element Size HX Cables Bending radius Conductor Insulation Cold Tail Lead CBS Heating Systems Safe t SLAB Installation Manual 3 Measuring the Resistance WARNING Remember to measure resistance The typical monitor shown at right will constantly monitor the heating wire 3 during the entire installation process If the wire is cut or damaged during installation this device sounds an alarm This will prevent burying a damaged LoudMouth LS wire below hardened concrete Using a digital Ohmmeter the resistance should be measured between the black and ty Ar cat ye t 9 di white conductors Compare the measured resistance to the resistance listed on the product label on the power lead Also measure the resistance between the black and ground wires and between the white and ground wires to test the insulation resistance Both should have infinite resistance If available CBS recommends using a meggar for this test with a voltage setting of up to 2500V Record the resistance on your Cable Resistance Certificate documenting the resistance at each stage of the installation is required for warranty purposes If the re
6. ble The Safe t SLAB cable must be laid out with even spacing over the entire area to be heated To ensure an accurate and easy method of installing the heating cable can be attached directly to the rebar or wire mesh using plastic electrical cable tie wraps 5 2 Center to center C C distance To determine the approximate c c distance with Safe t SLAB Cables the following formula below can be used or consult with the engineer responsible for the building construction To determine this Heated Area in m2 multiplied by 1000 Divided by The length of the selected cable s in Meters WARNING DO NOT CUT THE HEATING CABLE CBS Heating Systems Safe t SLAB Installation Manual CONCRETE INSTALLATION Wall Insulatlon Control box 1 Including thermostat Heating cable and contactor power lead conduit f Min 2 Inches Insulation 4 feet deep around perimeter oncrete Slab E Condult wlth floor sensor P 3 6 Inches from cable mld slab TT mln 2 Inches of concrete above amp below STET ALLERTA TIERE Ti ns Heating cables or mats mid slab rd Pig A gt MEC ES min 2 inches of concrete above amp below M OC LM ER LI cai or as specified by building engineer Te ee a ee Ng Optional vapor barrier HIHI PE TEE EST Optional Insulation I AHAHAHHA I Ee Sand Bed A METE HHAH ndisturbed Soil 6 Safe t SLAB Installation in Concrete Slab Step by Step STEP 1 PLAN YOUR LAYOUT Make a s
7. company s Customer Service department and provide the following information 1 Nature of the manufacturing defect 2 Date of purchase and if already installed date of installation 3 If installed name of electrician and flooring installer 4 Resistance readings taken by installer 5 Proof of purchase and serial number from product label Our Customer Service department will provide you with an authorization number and advise you on the next steps to complete your warranty claim Disclaimer This warranty gives you specific legal rights and you may also have some legal rights which may vary from state to state or province to province CBS Radiant Heating Systems hereby disclaims and it is as a condition of the sale that there are no implied warranties Some states and provinces do not allow limitations on an implied warranty so the above limitation may not apply to you CBS Radiant Heating systems can accept no responsibility for possible errors in catalogues brochures other printed materials and website information CBS reserves the right to alter its products without notice This also applies to products already on order provided that such alteration can be made without subsequent changes being necessary in specifications already agreed upon All trademarks in this material are property of the respective companies All rights reserved CBS Radiant Heating Systems www cbsheating com 0400 709 000 CBS Heating Systems Safe t SLAB
8. icate STEP 7 RECORD INFORMATION AND AFFIX LABELS Ensure that all resistances measured in steps 3 to 6 are recorded on the Cable Resistance Certificate The eight digit product code found on the CBS cable power lead must also be recorded on the above certificate nstall the electrical panel label at the electrical panel indicating the location of the cable Install the Warning label in a visible area of the floor for the duration of the construction It is also recommended that the label be kept in a suitable location on a permanent basis STEP 8 ENJOY THE COMFORT OF Safe t SLAB Heating The Safe t SLAB thermal storage heating system is now ready to use Increase the temperature gradually and adjust it until it reaches a level that suits your personal preferences Note that it may take several hours for the thermal mass to heat up the first time the system 1s powered or after extended periods of inactivity CBS Heating Systems Safe t SLAB Installation Manual A EXTENDED WARRANTY For a period of two 2 years from the date of purchase CBS Radiant Heating Systems warrants that the Safe t SLAB cable is free from defects in material design and workmanship The extended warranty is only valid if the warranty certificate has been properly completed and mailed and the installation is in accordance with the installation instructions The defective Safe t SLAB cable has to be inspected by or submitted to CBS Radiant Heating Sys
9. ketch of the area to be covered with heating cables Determine the location of fixtures such as drains pipes electrical conduits structural members and remember to keep a distance of 30cm around such obstacles All obstacles that shall be in the concrete slab should be installed prior to Safe t SLAB Cable installation to avoid damaging the cable You should also plan the location of the thermostats floor sensors locations and their conduit s location The start of the cable should be as close as possible to the thermostat s final placement For guidelines on cable installation see page 3 or 5 of this manual STEP 2 INSTALLING THE FLOOR SENSOR AND CONDUIT A floor sensor for high temperature protection must be installed in a rigid conduit The conduit protects the sensor and facilitates its replacement in the unlikely event of failure The sensor and the conduit may be installed during the actual construction work and connected at a later date Please observe the following 1 Ensure that the conduit is sealed before the concrete is poured 2 The conduit must be positioned between the heating cables This is usually at approximately the mid point of the concrete slab 3 CBS recommends keeping the conduit as short as possible and to minimize the number of bends in the conduit This will ease the installation of the sensor 4 Place the sensor inside the tube until it reaches the end of the conduit 5 The sensor and conduit sho
10. m of 50mm of rigid closed cell foam insulation Styrofoam or equivalent suitable for in ground installation Foamed urethane or polystyrene are not acceptable in their moisture reduced insulation properties Ensure that all sharp stones and debris are removed from the area where the heating cables are going to be installed Make sure the cable is not subjected to excessive tension or strain especially at the heating cable to cold tail lead splice It should not cross an expansion joint when installed in concrete For two or more slabs use of separate cables in each slab is recommended e At low temperatures the heating cable stiffens and may be difficult to work with To overcome this connect the cable to the mains for a brief period of time Ensure the cable is fully rolled out when this 1s done A minimum space of 30 cm should exist between the cables and the perimeter of the foundation and obstructions such as drains conduits and structural members There should be a minimum of 5 cm of concrete or sand above and below the heating cables Allow the concrete to set for at least 30 days before the heating cables are turned on There should not be any moving groundwater in the building area Natural moisture in the soil is acceptable If in doubt contact CBS Radiant Heating Systems CBS Heating Systems Safe t SLAB Installation Manual 5 General Safe t SLAB Installation Guidelines 5 1 Installing the heating ca
11. ms Safe t SLAB Installation Manual Remember to check that the supply voltage matches the voltage required for your particular Safe t SLAB product Extreme care must be used to ensure the in slab cables are not damaged when using sharp tools wheelbarrows heavy machinery shovels rakes or other implements Avoid walking on the cables during installation READ THESE INSTRUCTIONS BEFORE BEGINNING THE CONSTRUCTION OF THE FOUNDATION Never cut the heating cable Do not install the cables in such a manner that two heating cables touch cross or overlap Measure verify and record the actual resistance throughout the installation process 1 Out of the box 2 After installation 3 After laying the sand bed for sand bed installation 4 After the concrete slab is poured but not set 5 After connecting thermostat and or contactors Record these values in the Cable Resistance Certificate Failure to do so will void the warranty e The Safe t SLAB thermal storage heating system is most effective in single story buildings with tiled or stone or concrete floors If carpet wood or other flooring materials are to be used please consult with CBS radiant heating Systems The Safe t SLAB cable must be embedded in mortar or mortar mixture concrete sand or similar material Ensure no air pockets exist in the concrete or sand as this can cause damage to the cable The perimeter of the heated area should be insulated with a minimu
12. sistances do not match the expected values the cable may be damaged and need repair Contact CBS for a suggested repair procedure While not required you may also want to measure the resistance of the floor sensor It should be approximately 10kQ at room temperature 4 GENERAL NOTES Read before beginning foundation The installation shall be in accordance with the manufacturer s instructions and national and local electrical codes The installation shall be in accordance with Australian AS 3000 Wiring Regulations You must use a ground fault protection device GFCI or a Residual Current Device RCD All local codes concerning buildings electrical installations etc must be adhered to regardless of instructions provided in this manual If these regulations are in direct conflict with instructions stated herein please contact CBS Radiant Heating Systems It is important that this equipment is only installed by qualified electricians who are familiar with the proper sizing installation construction and operation of electric heating cable systems and the hazards involved The Safe t SLAB Cable system is designed for installation in concrete or sand applications only Metal structures or materials used for the support of or on which the Safe t SLAB Cable is installed must be grounded t is recommended to install the Safe t SLAB Heating Cable with a controller that contains an integrated temperature limiter CBS Heating Syste
13. tems Failure to comply with all of the foregoing will void this extended warranty CBS will when the customer has documented that a defect in the Safe t SLAB Cable was present at the date of delivery repair or supply a new Safe t SLAB Cable at CBS option All claims shall be made within the extended warranty period CBS shall not be liable for any claims made later than ten years from date of purchase CBS shall not be liable for any consequential and secondary costs or damages linked to the defect or replacement of the Safe t SLAB Cable CBS will be liable for any costs related to the dismantling of defective product and the installation of a new product however such liability is limited to the amount of five 5 times the initial product costs for each damage case THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED ON THE PART OF CBS RADIANT HEATING SYSTEMS CBS DISCLAIMS ANY WARRANTY EXPRESS OR IMPLIED OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE CBS NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON FIRM OR CORPORATION TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH SALE OR PRODUCT CBS SHALL NOT BE HELD RESPONSIBLE FOR DAMAGE TO PERSON OR PROPERTY CONSEQUENTIAL LOSS LOSS OF PROFIT LOSSES ON GOODS IN STORE OR THE LIKE WHICH MIGHT ARISE OUT OF THE FAILURE OF THE EQUIPMENT DELIVERED IRRESPECTIVE OF THE CAUSE INCLUDING FAULTY MANUFACTURE How to claim this warranty Contact the
14. uld be placed within 75 to 150mm of the heating cables and with at least 50mm of concrete or sand above and below 6 The floor sensor should be installed at least 1m into the heated area CBS Heating Systems Safe t SLAB Installation Manual 7 The floor sensor has a standard 3m lead that may be extended to a maximum of 50m with 20 AWG wire STEP 3 MEASURING THE RESISTANCE OF THE HEATING CABLE Using a digital ohm meter measure the resistance of the cable Compare the measured value with the resistance listed on the label of the power lead See page 2 for details Remember to record the measured resistances on the Cable Resistance Certificate Documenting the resistance at each stage of the installation is required for warranty purposes STEP 4 INSTALLING THE Safe t SLAB CABLE Installing the cable The cable is usually installed by attachment to the rebar or wire mesh of the foundation For details on this see page 3 and 5 of this manual The cables should be approximately at the midpoint of the slab but in all cases it is recommended to have at least 50mm of concrete above and below the cables The cold tail leading to heating junction box should have at least 30 cm of its length embedded in the mass material The remainder of the power lead should be in a conduit that extends to the thermostat or contactor The power lead may be extended if required Measure the resistance once again as outlined in step 3 and record the information
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