HEATBANK
Installation Instructions
Read Carefully Before Beginning Installation
THESE INSTRUCTIONS WILL ENSURE A SAFE AND RELIABLE thermal ENERGY STORAGE SYSTEM IF CAREFULLY FOLLOWED. FAILURE TO
FOLLOW THESE INSTRUCTIONS may RESULT IN UNSAFE OR UNRELIABLE INSTALLATIONS. IF YOU REQUIRE ADDITIONAL ASSISTANCE, PLEASE
CONTACT EASY HEAT for professional advice at 800/537-4732.
1.0 General
Heat Bank® heating systems are designed to heat moist
sand beds under concrete oors. The heat from the sand
bed heats the concrete oor which, in turn, radiantly heats
people and objects in the space above the oor. The sand
bed will usually take several hours to heat up (“charge”) and,
correspondingly, will continue to provide heat to the oor after
the system's power has been turned off. This enables the sand
to be charged during periods when electrical energy is less
expensive (“off peak”), usually at night, and discharged during
periods of higher energy cost, usually during the day. Due to
the slow response time of the Heat Bank system to changes in
temperature, and due to the fact that the Heat Bank system is
buried beneath the concrete oor and cannot be accessed
for service or replacement, a separate building heat source
that can be serviced and replaced as required must be
installed when the building is being constructed.
It is important to undertake a detailed heat loss of the planned
building. Heat Bank cables/mats will provide adequate heating
capacity for heat losses up to about 130 W/sq.m (12 W/
sq.ft). Buildings with heat loss in excess of 130 W/sq.m (12 W/
sq.ft). may also require supplementary “quick recovery” type
heating, although Heat Bank cables/mats equal to the total
heat loss should be installed. The major heat loss sources of
such buildings should also be reviewed to determine if these
sources can be modied to reduce heat loss. Contact Easy
Heat for further information.
Heat Bank heating systems are available as cable provided on
a spool or in pre-congured mats. Mats are typically laid onto
a sand bed (minimum 2" thick) and then covered with a sand
layer (minimum 2" thick). Spooled cables are typically plowed
into the center of a sand bed (minimum 4" thick).
Each heating zone will require two (different) thermostats:
an adjustable sensing thermostat to control oor temperature
at an appropriate setting, and to ensure heating temperature
does not exceed design requirements, a pre-set high limit
thermostat set for 54°C (130°F).
Insulation of perimeter foundation walls is required. Though
optional, insulation under the Heatbank systems sand bed
improves system performance.
It is important to ensure that the sand bed remains moist, as
this greatly enhances the amount of heat the bed can store
and promotes heat transfer away from the heating cables.
The installation of a 6-mil polyethylene vapor barrier above the
sand bed will help to retain moisture in the bed.
It is recommended the heating system be designed to use
several smaller wattage units rather than one large wattage
unit. Only 2 IDENTICAL 240 VAC units can be installed in series
at 480 VAC. A scaled drawing must be made showing the
Heatbank system layout, related branch circuitry, junction
boxes and controls. Retain this drawing for future reference, as
warranty is void without this drawing.
2.0 Planning
For maximum efciency it is recommended that Heat Bank
systems utilize a tightly compacted, moist sand base of at least
4" depth, although, typically, sand beds are 10 to 12" deep.
Sand bed depths of up to 18" are possible; sand bed depth
is determined by the building design and geographic region.
Use only washed masonry mortar sand (or any sand complying
with ASTM C-144-97) for the sand bed. This type of (ne) sand
minimizes moisture loss from the sand bed. The cables/mats
must be positioned with at least 2" of compacted sand below
the cables/mats and 2" of compacted sand above the cables/
mats. The sub-base below sand bed can be sand, gravel, clay,
engineered backll, or native soils free of organic matter. Natural ground moisture or infrequent high water does not adversely
effect the system, but moving water, such as underground
springs and tidal uctuations, or continuous standing water will
signicantly reduce system efciency.
Due to the proximity of heavy machinery to the heating
cables/mats during cables/mats installation and subsequent
oor placement, there are risks of cables/mats damage by
such machinery. Workers must be cautioned to report any
possible cable damage immediately so that necessary repairs
can be made prior to completion of the pour. All repairs must
be in compliance with standards established by the applicable
code enforcement authorities.
3.0 Site Preparation and Heat Bank® System
Installation
3.1 All underground plumbing and electrical utilities shall be
routed in the sub-base and backlled with
well-compacted material. Structural footings, walls,
piers, etc., adjacent to or within the sand bed must be
completed.
3.2 Excavate the sand storage bank by grading this area
to the design thickness of the sand bed below the
underside of the slab. Remove stones or any other debris
that may be present.
©2015 Easy Heat www.easyheat.com 11001-088 Rev. 11
3.3 Insulate perimeter foundation walls with 2" Styrofoamtm
Type SM or equivalent rigid closed cell extruded
polystyrene. Extend to a depth below nished oor of
at least 4 feet to reduce side heat loss. If foundation
does not extend to this depth, it is recommended that
insulation wrap around footing and continue downward
without disturbing soil bearing. Where nished exterior
grade is such that foundation is exposed (such as at
loading docks), insulation thickness should be increased
to 4".
3.4 For spooled cable, ll the graded area with the design
thickness of compacted washed masonry sand. For
mats, cover the graded area with about one third of the
design thickness of the sand bank, but not less than 2".
Use only ne sand for the storage bank.
3.5A Initial Cable Testing
Insulation Resistance Test: Connect a meggohmmeter
between the copper grounding braid and the
two conductors connected together. Set the
meggohmmeter at 500 Vdc(minimum)and measure
the resistance. The resistance must be 50 Megohms
minimum.This test assures that the cable has not been
damaged during shipment or subsequent handling.
Resistance Test: Connect a nohmmeter between the
two conductors of the cable. Measure the resistance.
Be certain that the resistance is appropriate for the
marked wattage and voltage. Repeat above test for
each cable used in the installation. Record readings
on Installation Test Record Form included with these
instructions.
3.5B Initial Mat Testing
Insulation Resistance Test: Connect a meggohmmeter
between the copper grounding braid and the inner
conductor on one lead of a mat. Ensure the other lead
is isolated and the heating element is not in contact
with the ground braid. Set the meggohmmeter at
500 Vdc(minimum)and measure the resistance. The
resistance must be 50 Megohms minimum. This test
assures that the mat has not been damaged during
shipment or subsequent handling.
Resistance Test: Connect an ohmmeter between
the inner conductors of the two leads of the mat.
Measure the resistance. Be certain that the resistance
is appropriate for the marked wattage and voltage.
Repeat above test for each mat used in the installation.
Record readings on Installation Test Record Form
included with these instructions.
3.6 Install spooled heating cables in sand as per spacing
from Spacing Chart. For mats, lay mats onto sand.
Ensure that cables are not damaged during installation.
Do not pull or bend cold lead factory splice. Care
must be taken that cable does not bunch, kink, twist or
overlap. Each spooled cable has a marking indicating
the midpoint of the cable to use as a benchmark during
the installation.
3.7 Do not install heating cables/mats within 6" of any
obstruction, such as plumbing, drains, conduits,
structural members, etc.
3.8 The entire heating cables/mats, including the cold
lead factory splice, must be embedded in the sand
at a uniform depth and must be installed with uniform
spacing.
3.9 Install ¾" (maximum) rigid metal or intermediate metal
conduit for high limit thermostat. Close terminal end
of conduit with threaded metal pipe plug or cap such
that sensing bulb can be fully inserted to deadend.
Attach the nal 3–6" of conduit directly to a heating
cable using vinyl electrical tape (do not use tie wraps).
Choose a point of attachment:
• At least (2 feet) into the heating cable array.
• Within the range of the 10-foot capillary tube.
• That requires a single 90° conduit elbow/bend.
(Multiple bends will impede bulb insertion.)
3.10 Install cold lead conduit(s) and pull cold leads through
conduit. Identify all cold lead pairs. If for whatever
purpose, factory labels are removed from cold leads,
they shall be afxed to the branch circuit panel to
identify the pertinent supply circuits.
3.11 Complete sand cover over mats, taking extreme care
not to damage cable.
3.12 Compact sand to provide a homogenous, stable base
for the slab.
3.13 IMMEDIATELY PRIOR TO CONCRETE POUR, RETEST
CABLES/MATS FOR CONTINUITY AND INSULATION
RESISTANCE.
3.14 Prior to the concrete pour, wet sand with a ne water
spray to further compact the sand and prevent the
concrete from curing too quickly. Continue to wet sand
until fully and evenly saturated with water.
3.15 Install vapor barrier atop sand bed. Overlap sheeting
at least 6". Apply additional sand (1") on top of vapor
barrier to ensure adequate securement.
3.16 Install ¾" (maximum) metal or PVC conduit for oor
sensing thermostat. Close terminal end of conduit to
exclude concrete and situate at the mid-level of the
slab directly above the heating cable array and within
the range of the 10-foot capillary tube.
3.17 IMMEDIATELY AFTER CONCRETE POUR, RETEST CABLES/
MATS FOR CONTINUITY AND INSULATION RESISTANCE TO
ENSURE THAT NO DAMAGE HAS OCCURRED DURING
POUR. DO NOT ENERGIZE CABLES/MATS AT THIS TIME.
3.18 Allow minimum 2 weeks for concrete to cure prior to
energizing the system.
4.0 Cables/Mat Power Connection
All wiring and installation of electrical equipment and devices
comprising the Heat Bank system shall be in accordance with
all requirements of the National Electric Code and all
applicable local electrical and building codes, regulations, and
inspection procedures.
www.easyheat.com
Loading...