Installation Instructions MINERAL INSULATED (M.I.)

Transcription

1 Installation Instructions MINERAL INSULATED (M.I.) Radiant HEATINg Cable Assembly Contents Section 1. Section 2. page overview 1.1 Precautions Cable and components General accessories Tools recommended Site plan Cable storage Cable labeling Cable testing Site preparation Proper cable handling N.E.C. code Conduit and circuit wire... 3 InstallatION 2.1 General Information Electrical 214 rough-in Using the FW-CS FloorWarner Subfloor installation Embedding over subfloor installation Embedding concrete slab Floor coverings Completing the installation...11 Section 3. Testing and trouble-shooting 3.1 Pre-installation testing Monitoring cable during installation Final testing Maintenance Trouble-shooting and technical support...12 Warning: Mineral Insulated Cable must be installed by a qualified electrician. All assembly, installation, and test instructions must be followed. Improper installation can result in property damage, serious injury, or death due to electric shock. Please call Delta-Therm Corporation at with any installation or operating questions. DELTA-THERM Corporation,6711 Sands Road Suite A, Crystal Lake, IL (847) Fax (847) (800)

2 Section 1. Overview 1.1 Precautions Please read these installation instructions and all instructions included with kits prior to installation. Observe all warnings. Visually inspect the cable for damage. The cable must not be cut, nicked or worn. Do not install damaged cable. Installer must be knowledgeable of local electrical codes, electrical installation, and flooring. M.I. cable installation must comply with all electrical codes and building requirements. Floor thermostat required. M.I. cable must be embedded. Limit walking on the M.I. cable. The non-heating M.I. cable cold leads may be shortened, but the product label must remain in the electrical junction box. Leave all UL and CSA labels on the M.I. cable assemblies. Ensure that the branch circuit breaker is appropriately labeled, and has sufficient capacity to accommodate the M.I. cable load. Delta-Therm recommends using a dedicated circuit. Do not bend cable within 3 of a splice or termination sleeve. Do not bend the cable tighter than 3 inside diameter. Do not twist, kink, or spiral the M.I. cable assembly. Do not pull the M.I. cable from the coil in a helix manner. Unreel the M.I. cable. Do not cut or alter the heated section of M.I. cable. Do not make splices or field repairs in the M.I. cables without consulting Delta-Therm. Do not place built-in cabinets or other furniture with solid bases on top of the heated area of the floor (this could trap heat and cause dangerous overheating). Do not allow the M.I. cable to overlap or cross over itself. Do not allow the M.I. cable assemblies to cross over an expansion joint. Do not install M.I. cable in or over walls, or in closets. Do not install M.I. cable closer than 2 (25 mm) from a wall or another heat source. Do not install M.I. cable on wood subfloor or under combustible floor coverings. Do not apply power to M.I. cable until the floor has fully cured. Use ground fault protection as required by codes. Ground M.I. cable in accordance with prevailing electrical codes. Log all readings and cable info on the warranty card. Each M.I. cable assembly is factory terminated M.I. cable assemblies are custom designed for each heated area. Install M.I. cable assemblies only in the designated area. 1.2 CABLE AND COMPONENTS Each M.I. cable assembly is factory terminated. Each M.I. radiant heating cable assembly includes a base kit. Each base kit includes: (1).75 conduit body (C or T type) (1) Bag of Delta Dry hydroponic powder (1) Piece of duct-seal Required pressure connector(s) Each M.I. cable has a UL or CSA label attached to the THWN cold lead within 3 of the brass terminating sleeve stating in order: Cable type prefix Number of conductors Cable resistance Cable length in feet Operating voltage Current draw Total wattage Watts per lineal foot Note: Do not remove the UL or CSA label. 2

3 Section 1. Overview 1.3 GENERAL ACCESSORIES 1.4 TOOLS RECOMMENDED 1.5 site plan 1.6 Cable storage 1.7 cable labeling 1.8 cable testing 1.9 site preparation 1.10 PROPER CABLE handling 1.11 NEC Code 1.12 CONDUIT AND CIRCUIT WIRE Accessories Product Product Description Number Number Description UDG-4999 Floor Warming Thermostat DT-XXPXXX Enclosed Contactor Panel PP-GS-75 Galvanized Steel Cable Strapping LNR-X Low Noise Relay Panel PP-SS-75 Stainless Steel Cable Strapping FW-CS Continuity Monitor with Audible Alarm Standard electrician s hand tools. Floor sensing thermostat. Standard electrical fittings and supplies. Screwdriver, drill, tin snips, fish tape, and standard hand tools. Pencil, marker, or chalk line to mark M.I. cable layout before installing. Embedding material, acceptable are: concrete, thin-set, self-leveling, and cement. Deep electrical junction box, H./W./D. 4 /4 /2 with 3/4 conduit knock-outs and singlegang drywall ring. One or more 3/4 thin-walled metal conduit(s), 90 degree standard bends with offset, rigid conduit for cement. 3/4 flexible conduit may also be installed. Digital Multimeter, ohmmeter, and insulation resistance meter. Cement backer board (for wood subfloor applications) 500 VDC insulation resistance tester. Delta-Therm offers engineered drawing services as outlined in our Price List. If drawings were ordered, please compare the drawing bill of materials to materials supplied with your order and verify that you received all of the Delta-Therm components. Before starting the installation verify the proper location and layout of heating cable(s), control(s), and/or accessories. All M.I. cables should be stored in a cool, dry location. Cables should be protected from damage. Following the cable testing instructions in section 3, test all cables removed from storage and record the readings on the warranty card. Delta-Therm Mineral Insulated Heating Cables are UL listed and CSA certified for radiant heating installations. Each cable has a UL or CSA label attached to the THWN cold lead within 3 (76mm) of the metal sleeve. The label states the following information in order: cable type (prefix, number of conductors, and cable resistance), cable length, operating voltage, current draw, total wattage, watts per lineal foot, and cold lead length. The cable has a standard THWN cold length of 10 (3m). Please refer Section 3 for all cable testing procedures. Review installation, engineering, electrical, and or architectural drawings prior to installation. Verify that available voltage is the same as the cable operating voltage indicated on the UL or CSA label. Install conduit from the cable feed points to an indoor or dry junction box, continuing to the power panel per site plan. Install appropriate grounding system per prevailing electrical code. Always unroll the coil of M.I. cable. Do not pull the cable in a helix fashion. Please refer to Detail 2 and Detail 4 to review single and dual conductor cable finished assembly and base kit components. Please consult NEC Article 424, Fixed Electric Space-Heating Equipment Article Installation of Cables in concrete or Poured Masonry Floors. The cable assemblies require a permanently wired and grounded conduit system. Use only UL Listed (CSA Certified) weatherproof junction boxes. 3

4 2.1 GENERAL INFORMATION Before starting the installation please refer to Section 1.5 Site Plan, Section 1.9 Site Preparation, and test cables following the directions in Section 3.1 Pre-Installation Testing. Please refer to Detail 2 and Detail 4 to review single and dual conductor cable finished assembly and base kit components. To calculate cable spacing, find the square footage of the area to be heated and divide by the length of cable given on the UL or CSA label. Multiply this number by 12 to get the approximate cable spacing in inches on center. Example Calculating Cable Spacing: 100 sq. ft. (30 sq.m) area 200 ft. (60m) of cable 100/200 = x 12 = 6 (152 mm) cable spacing Single conductor M.I. cable must begin and end at the power supply. Dual conductor M.I. cable only begins at the power supply. Start your initial M.I. cable run at the power supply and run the M.I. cable 2 in from the perimeter wall to the farthest corner of the room. Next begin laying M.I. cable runs, at the calculated spacing from step 1, to fill in the open area. CLIPS STRAPPING POWER LOCATION FW-17 Detail 1. Typical M.I. cable layout. 3/4" "T" CONDULET FITTING THWN COLD LEADS PRESSURE CONNECTOR POTTING TUBE THERMAL GRADIENT HOT-COLD SPLICE Detail 2. The single conductor M.I. radiant heating cable assembly is typically installed in slabs. The assembly is factory terminated and ships with a base kit as described in section

5 4" 22" Detail 3. Plan of single conductor M.I. cable entry into the T type conduit body (TB). Pull cold leads through conduit and instal duct seal. Fill the conduit body with Delta-Dry power, install gasket and cover. THHN COLD LEADS PRESSURE CONNECTOR HOT-COLD SPLICE 3/4" "C" CONDUIT FITTING END CAP Detail 4. Dual conductor M.I. radiant heating cable assembly is typically installed in stairs. The assembly is factory terminated and ships with a base kit as described in section ELECTRICAL rough-in 1. Use the established location of the electrical supply in the room to be heated as your starting point. Each M.I. cable must begin where power is supplied. 2. Install a deep electrical junction box, H./W./D. 4 /4 /2 with 3/4 conduit knock-outs and a single gang drywall ring mounted vertical 58 above finished floor height. 3. When applicable, notch the 2 x 4 plate beneath the electrical junction box for the 90 degree conduit bend to sit below the floor surface. Notch deep enough for the embedding material to lay flush. 4. Install at least one 3/4 thin-walled metal conduit from the electrical junction box to the floor. Use rigid conduit for cement. 5. Bend one end of the metal conduit on a 90 degree angle. The conduit may require an offset to position it in the wall. 6. Install the 90 degree bend (in the floor notch when applicable) and connect the conduit to the junction box. 3/4 flexible conduit may also be used. 7. The UDG-4999 thermostat is supplied with a thermistor sensor to be embedded in the floor to measure floor temperature. The thermistor sensor can be installed in 1 of 3 ways: 8. Delta-Therm recommends installing the thermistor sensor in conduit to protect it from damage during installation. The thermistor sensor can be installed in a stubbed conduit and clipped to the surface with a small clip. The thermistor sensor is not installed in any conduit and is clipped to the surface with a small clip. 9. Repeat Steps 4 and 5 if the thermistor sensor is being installed in conduit. 1/2 conduit can be used. 10. Connect power feed to electrical junction box. 5

6 2.2 ELECTRICAL rough-in 3/4" CONDUIT NOTCH FLOOR PLATE AS REQUIRED M.I. HOT/COLD SPLICE 48" TWO GANG JUNCTION BOX FOR UDG-4999 THERMISTAT 3/4" UNILET M.I. THERMAL GRADIENT SECTION 1/2" CONDUIT WITH SENSOR PRE-PUNCHED STRAPPING CAP END OF CONDUIT FOR UDG-4999 THERMISTORE SINGLE CONDUCTOR WIRE M.I. WITH DUCTAPE Detail 5. Typical single conductor M.I. cable rough-in and cable layout. It is recommended that the electrical junction box be installed at 48 above finished flooring and preferably on an inside wall. TWO GANG JUNCTION BOX FOR UDG-4999 THERMISTAT 1/2" CONDUIT WITH SENSOR NOTCH FLOOR PLATE AS REQUIRED END TERMINATION 48" 3/4" CONDUIT 3/4" UNILET M.I THERMAL GRADIENT SECTION PRE-PUNCHED STRAPPING FW-10 DUAL CONDUCTOR M.I. CAP END OF CONDUIT FOR UDG-4999 THERMISTORE WIRE WITH DUCTAPE Detail 6. Typical dual conductor M.I. cable rough-in and cable layout. It is recommended that the electrical junction box be installed at 48 above finished flooring and preferably on an inside wall. 6

7 2.3 using the FW-cw floor warner 1. Momentarily switch ON the FloorWarner to ensure the alarm will sound. 2. Attach the ground wire from the junction box to the FloorWarner terminal with the green wire leading to the other side of the terminal. 3. Connect the one inner orange cold lead to the terminal with the black lead wire connected to the other side of the terminal. 4. Connect the other orange cold lead with the red lead wire connected to the other side of the terminal. 5. Turn the FloorWarner slide action switch to the ON position, the test unit should be silent. 6. Use a jumper wire to touch the terminal screw of the green terminal to the terminal screw of the red terminal. The FloorWarner s audible alarm should sound. 7. With the FloorWarner switched ON, remove the orange cold lead cable from the red terminal. The audible alarm should sound. Reconnect the wire and the alarm should stop. Note: If using PVC conduit, connect green terminal to ground wire from conduit body. Note: FloorWarner test does not substitute for M.I. cable continuity or insulation resistance testing. DUAL CONDUCTOR M.I. CABLE CONDUIT BODY ON OFF GROUND ORANGE BLACK GREEN RED Detail 7. FloorWarner wiring diagram. 7

8 2.4 subfloor installation Before starting the installation please refer to Section 1.5 Site Plan, Section 1.9 Site Preparation, and test cables following the directions in Section 3.1 Pre-Installation Testing. Please refer to Detail 2 and Detail 4 to review single and dual conductor cable finished assembly and base kit components. 1. Attach a length of strapping (with the tabs facing up) parallel to the longest unobstructed wall and 6 in from the wall. Secure strapping every 12 to 16 with the supplied screws. 2. Cut another length of strapping to run parallel against the opposite wall. Install this length of strapping 3-1/2 in from the wall. 3. Before installing the M.I. cable, clear all surfaces on which the M.I. cable is to be fastened of sharp edges and debris. 4. Check continuity and resistance value of the M.I. cable using an ohmmeter. Verify resistance with the M.I. cable label. 5. Measure insulation resistance using an insulation resistance meter. Insulation resistance should be at least 10 megohms from conductor to braid. 6. Attach conduit body to 3/4 conduit stubbed into floor. 7. Feed the leading cold lead up through the conduit to the junction box. 8. Continue laying M.I. cable 2 in from the wall around the perimeter of the room to the farthest corner and secure M.I. cable using small clip. 9. Lay M.I. cable runs at calculated spacing to fill in open floor space. As you near the end of laying the M.I. cable runs, evaluate the remaining M.I. cable length and remaining area. 10. M.I. cable spacing can be adjusted in low traffic areas and around the perimeter of outdoor facing walls. 11. If there is a shortage of M.I. cable at this point you can space the M.I. cables further apart or omit areas that are low traffic. If there is an excess of M.I. cable at this point you can tighten M.I. cable spacing across the entire area, in low traffic areas, or around the perimeter of outdoor facing walls. 12. For short heating cables reduce or remove loops in areas not subject to foot traffic 13. Verify that M.I. cable layout is complete before shortening the cold lead. Cut cold lead leaving approximately 6 sticking out of the junction box. 14. Strip back 1/2 of insulation for the power connection. 15. Retest M.I. cable for continuity and insulation resistance to ensure that no damage was incurred during installation. Refer to Section Attach the Delta-Therm FloorWarner. Refer to Section 2.3. NOTES: Always heat areas that will be contact with feet. Do not cut, alter, or shorten the heated section of the M.I. cable. FloorWarner test does not substitute for M.I. cable continuity or insulation resistance testing. Use adequate number of clips and strapping to maintain cable spacing. Do not allow cable to crossover itself. 2.5 EMBEDDING OVER SUBFLOOR InstallatION Embed the M.I. cable in a thin skim coat layer of thin set or other mortar and thin set tile, marble, or stone over the skim coat layer. Remember to check with the embedding material manufacturer for curing time. 8

9 2.5 EMBEDDING OVER SUBFloor InstallatION THIN SLAB (GYPSUM-BASED MATERIAL) PLYWOOD INSULATION Detail 8. M.I. cable embedded in thin slab over plywood. TILE/STONE LATEX PORTLAND CEMENT MORTAR BOND COAT BACKER BOARD MORTAR BED PLYWOOD INSULATION Detail 9. M.I. cable embedded over backer board with tile floor covering. 2.6 embedding in concrete slab Before starting the installation please refer to Section 1.5 Site Plan, Section 1.9 Site Preparation, and test cables following the directions in Section 3.1 Pre-Installation Testing. Please refer to Detail 2 and Detail 4 to review single and dual conductor cable finished assembly and base kit components. 1. M.I. cable assemblies may be fastened to concrete rebar or a reinforcing wire mesh type of substrate, and concrete can be poured over the cable. 2. Inspect the area to be heated and verify that the M.I. cable assembly depth will be between 1 and 3 (25mm and 76mm) below the finished surface. M.I. cable assemblies installed deeper than 3 (76mm) will have a longer warm up time at the surface and potentially less heat at the surface. 3. Using spray paint, chalk lines or another means, mark the layout pattern and spacing on the rebar/mesh or subfloor. Refer to the layout drawings for the pattern and spacing. 4. Unpack and test M.I. cable assemblies per testing instructions on the first page. Record readings on the warranty test results card. 5. Uncap conduit and swab if necessary to remove all moisture. Install the 3/4 (19mm) conduit body (TB) so that the opening is face up. Install the pressure connectors into the TB. Feed one cold lead through a pressure connector until the metal termination sleeve is mid-way into the pressure connector. Wrap the UL or CSA label around the cold lead to feed through the connector. Tighten the connector. 6. Wrap the thermal gradient section around the TB. 7. Roll the cable out carefully and fasten to the substrate using metal clips or nylon cable ties. 9

10 2.6 embedding in concrete slab 8. Bring the second lead back and wrap around the TB. 9. Pull the cold lead through the pressure connector until the metal sleeve is mid-way through the connector. Tighten the connector and pull the leads through the conduit to the junction box. 10. Test the cables for insulation resistance and total resistance and record the readings on the warranty card. 11. Install the duct seal between the TB and the conduit. Fill the TB with Delta-Dry powder and seal with a gasket and cover. NOTE: The conduit body is not a splice box. The TB is embedded in the concrete, gypsum, or mortar. FINISHED FLOOR CONCRETE SLAB M.I. S 2"-3" BELOW SURFACE GRAVEL BASE UNDISTURBED EARTH Detail 10. Typical embedded M.I radiant heating cable assembly in a single pour structural slab. THIN SLAB (GYPSUM-BASED MATERIAL) M.I. REBAR/WIRE MESH SLAB Detail 11. Typical embedded M.I radiant heating cable assembly in a single pour over a slab. 10

11 2.7 Floor coverings Total combined flooring R-values are not to exceed R-2.5. R-values for flooring material are available from the flooring manufacturer or other sources such as the Radiant Professionals Alliance (RPA). Material R-Value Tile R-0.25 Wood Flooring R thick Carpet R thick Carpet R-2.1 Note: The floor covering directly on top of the embedding layer must be of non-combustible material (tile, marble, stone, cement, gypcrete, etc) and at least.25 in thickness. Do not install combustible flooring (wood, carpet, etc.) directly on top of a.25 embedding layer. 2.8 completing the installation After the flooring has been installed, remove the FloorWarner or meter, recheck continuity and complete all wiring. Follow the instructions included with the UDG-4999 thermostat. Energize the M.I. cable after the floor has properly cured and allow sufficient time for the floor temperature to rise. 120 VAC L N *CIRCUIT BREAKERS PROVIDED BY OTHERS* CB 120VAC 15A MAX OUT OUT IN/SENSOR IN/SENSOR A B C D L1(L) L2(N) LINE 120 / 240 VAC LOAD 1800W / 3600W MAX 15A SENSOR Detail 12. UDG-4999 thermostat 120 VAC wiring diagram. 208/240 VAC *CIRCUIT BREAKERS PROVIDED BY OTHERS* L2 L1 N CB 240VAC 15A MAX OUT OUT IN/SENSOR IN/SENSOR A B C D L1(L) L2(N) LINE 120 / 240 VAC LOAD 1800W / 3600W MAX 15A SENSOR Detail 13. UDG-4999 thermostat 208/240 VAC wiring diagram. 11

12 Section 3. Overview 3.1 Pre-Installation Testing Unpack the M.I. cable and test each cable for insulation resistance (IR), and total resistance (TR). To test TR, connect each lead of the ohmmeter to each M.I. cable cold lead conductor. Test in accordance with the meter manufacturer s instructions. Compare TR reading from ohmmeter to calculated TR (multiply the heated length of cable by the cable resistance value found on UL/CSA label). The ohmmeter reading should be within 10% of the calculated TR. To test IR, connect one lead of the 500 VDC insulation resistance tester to one cold lead conductor and the other lead to the M.I. cable metal sheath. Test in accordance with the meter manufacturer s instructions. IR reading should be greater than 10 megohms. Please enter the TR and IR readings on the warranty card. 3.2 Monitoring M.I. Cable During Installation 3.3 Final Testing 3.4 Maintenance 3.5 Trouble-Shooting AND Technical Support Repeat the steps as described in Section 3.1 and enter the information on the warranty card. If there is a change in the meter reading, please check the cable for damage, as well as any power connections, splices, and end terminations. Repeat the IR test steps as described in Section 3.1. To test TR, connect each lead from the ohmmeter to the two cold leads that will be attached to power. Enter the information on the warranty card. If there is a change in the meter reading, please check the cable for damage, as well as any power connections, splices, and end terminations. Annually check system for loose or damaged cable. If during any test the meter readings vary by +/- 10% from the previous test, stop the installation and investigate. Please check for pinched or crushed cables, test splices, test power connections, test end terminations, and repair accordingly. Check for water in all junction boxes or conduit. Any faults should be repaired by a qualified electrician or factory technician before the final pour is made. For additional trouble-shooting and repair procedures, please contact Delta-Therm technical support at Please be prepared to provide: Part numbers for all installed equipment IR and TR readings on all installed cables Verification that incoming voltage matches design voltage of Delta-Therm equipment Verification that you have checked all wiring, junction boxes, etc. Digital photos of installed equipment If you have any questions or comments about these instructions or your installation please call Delta-Therm at CA_MI_FW_1203_II 12