ELEKTRA TuffTec 30, TuffTec 30/400 V Installation Manual

www.elektra.eu

• Tuff Tec™ 30

• Tuff Tec™ 30/400 V

TuffTec™

Instrukcja instalacji

PL

Installation manual

UK

ELEKTRA

Инструкция по монтажу

RU

HEATING CABLES

Applications

ELEKTRA TuffTec™ heating cables are intended
for effective prevention of snow and ice deposi­tion on:

• driveways, roads, footbridges, loading ramps

and parking spaces with asphalt or concrete
surface,

• roofs covered with bituminous materials,

• gutters and downpipes requiring the output of

60 W/m.

Characteristics

ELEKTRA TuffTec™ heating cables feature the
following characteristics:

• high mechanical strength

- cables intended for installations characte­rised by increased risk of mechanical damages

• high thermal properties

- max. operating temperature: +110°C

- max. exposure temperature (10 min): +240°C

- min. installation temperature: -25°C

• UV-Resistant

• resistance against chemical agents, including

bituminous substances.

3

Heating Cables

ELEKTRA

ELEKTRA TuffTec™ cables are intended for
installation in the conditions of increased risk
of mechanical damages, e.g. in case when
concrete consolidation machinery is utilized for
surface works.

Due to their exceptionally high thermal properties,
as well as resistance against bituminous
substances, the TuffTec™ cables can be safely laid
in asphalt.

Also, the cables can be laid on the roofs with
bituminous coverings.

FEP (Teflon)
first insulation layer

Multi-wire
heating core

HDPE second
insulation layer

Tinned
copper braiding

UV resistant
HFFR outer sheath

Construction of the ELEKTRA TuffTec™ heating cable

4

• “cold” power supply conductor

• ELEKTRA TuffTec™ heating cable

• connecting joint between the power supply

conductor and the heating cable

1

2

3

1

2 3

Technical properties

The ELEKTRA TuffTec™ heating cables are pro­duced in ready-made units, manufactured in
compliance with the EN 60335-1 standard.

The ready-made units include heating cables
terminated with a power supply conductor.

Power output 30 W/m

Power supply voltage 230 V, 400 V ~ 50/60 Hz

Cable diameter ~ 6.8 mm

Min. installation temperature -25°C

Max. operating temperature +110 ° C

Max. exposure temperature (10 min.) +24 0 ° C

Power supply conductors 1 x 4 m; 3 x 1.5 mm²

or 3 x 2.5 mm² rubber
insulation and outer
jacket

Heating cables double-core, screened,

single-side powered

Insulation double layer, FEP + HDPE

Outer sheath UV-resistant HFFR

Rated power output tolerance +5%, -10%

Min. cable bending radius 3.5 D

IP rating IPX7
System certication according to ISO 9001

IQNET, PCBC

Markings CE

5

Heating Cables

ELEKTRA

Single-side powered
heating cables

Self-adhesive label

Note:

ELEKTRA TuffTec™ 30 heating cables are designed
for the rated voltage 230 V/50 Hz, and TuffTec™
30/400 heating cables – for the rated voltage
400 V/50 Hz.

Heating cables’ heating output may vary with
+5% and -10% from the nameplate values.

!

The label features the following pictograph:

Note:

Never cut the heating cable.

Never trim the heating cable, only the power

supply conductor may be trimmed if required.

Never squash the “cold tail”.

Do not ever undertake on your own any attempts
to repair the heating cables, and in case any
damage is detected, report the damage to an
ELEKTRA authorized installer.

Never stretch or strain the cable excessively, nor
hit it with sharp tools.

Do not install the heating cables when ambient
temperature drops below -25°C.

!

6

General information

Surface protection against snow
and ice deposition

When protecting external areas from snow and ice
deposition, it is required to assess the required heat
output value per m

2

of the surface. Recommended
heat output depends on the regional climate condi­tions, i.e. minimum ambient temperature, snowfall
intensity and wind strength.

Higher output is required if the heated area is:

• exposed to wind from below:

- bridges, stairs, loading ramps, overpasses

• located in a regions of intense snowfall

Ambient

temperature

Heat output

[W/ m

2

]

> -5°C

-5°C ÷ -20°C

-20°C ÷ -30°C
< -30°C

200
300
400
500

Note:

Never lead the end joint and the connecting

joint between the heating cable and the power
supply conductor out of the surface. Both joints
must be placed – depending on the type of sur­face – within the layer of sand, dry concrete or
directly in concrete.

Never bend the joint and end seal.
Heating cables must be installed according to

the Instructions.
Mains connection of the heating cables should

be performed by an authorized electrician.
Power supply conductors (”cold tails”) in asphalt

should be positioned in the protective metal
installation conduit. Alternatively, power sup­ply conductors can be led out of the area where
asphalt will be poured out.

!

7

Heating Cables

ELEKTRA

Applying insulation layer to the surfaces exposed
to wind from below can improve effectiveness.

Depending on the cable spacing, it is possible
to obtain required output per m

2

of the heated

area.

Cable spacing cannot drop below 5 cm.

To protect large areas against snow and ice depo­sition, one option is application of 400 V voltage
heating cables, which would evenly load the elec­tric circuit. Application of such cables would also
reduce installation works, limiting the required
number of heating cables.

Heat output 30 W/m

[W/m

2

] [cm]

300
375
430
500
600

10

8
7
6
5

Protection of bituminous roofs,
gutters and downpipes against snow
and ice deposition

Thanks to their exceptionally high resistance

against damaging inuence of any bituminous

substances, ELEKTRA TuffTec™ heating cables are
ideally suited for the purposes of heating roofs
covered with tar paper, roof tiles or bituminous
shingles.

Selection of the required heat output depends on
the regional climate conditions of the zone where
the installation is to be positioned.

8

It is recommended to heat gutters and roof edges
adjoining them on the width of approximately 50
cm, as well as roof channels. Effective heating

of these elements will facilitate roof outow of

melted snow, and will prevent icicles.

Tar paper-covered roofs are usually at (up to

15°) and require higher heat output. Especially
roof valleys and channels are exposed to snow
deposition.

Heat output for the moderate climate zone

ELEKTRA TuffTec™ heating cables can be installed
in gutters or downpipes of buildings located
in cold climate zones, where it is also necessary
to execute high heat output, i.e. 60 W/m by
double-laying the cables in gutters.

Application Heat output

[W/ m

2

]

Roof channels 200-300

Roof edges approx. 200

Roof stretches
excessing the building’s facade

approx. 300

9

Heating Cables

ELEKTRA

Anti-snow and anti-ice controls

• for the protection of surfaces

ELEKTRA ETOG2 controller – max. load up to 3x16 A.
For applications in extended heating systems.

ELEKTRA ETR2 controller – max. load up to 16 A,
total output of installed heating cables must not
exceed 3600 W. As standard, equipped with one
temperature and moisture sensor with installation
tube.

Controls

Properly selected control system will ensure ad­equate operation of the heating system only during
snow and freezing rainfall. A temperature control­ler with a temperature and moisture sensor will
automatically recognize the weather conditions.
The heating system will be then kept on standby
and only switched on when actually necessary. For
this purpose, DIN-bus installed controllers ELEKTRA
ETR2 and ETO2 can be utilised.

10

• for the protection of roofs,

gutters and downpipes

ELEKTRA ETR2R controller – as standard,
equipped with one air temperature sensor and
moisture sensor.

ELEKTRA ETOR2 controller – as standard, equipped
with one air temperature sensor and moisture sen­sor. Additional moisture sensor can be connected
to this controller, which will enable protection of
two independent roof areas.

Additionally, it is possible to control two indepen­dent areas, e.g. a garage driveway and gutters,
with one controller only.

As standard, equipped with one temperature and
moisture sensor and an installation tube. Addition­al temperature and moisture sensor can be con­nected to this controller, which will enable protec­tion of two outdoor areas.

11

Heating Cables

ELEKTRA

To maintain xed positioning of the cable and

steady spacing conforming to the calculated
values, the cables need to be attached with the
ELEKTRA TMS installation tape (the tape should be
positioned with the distances of 40 cm) or instal­lation mesh of 5 cm x 5 cm grid, made of Ø 2 mm
wire.

The heating cable layout should be commenced
from the side of the power supply conductor,
in such a way to enable easy reach to the switch­board.
If the cold tail needs to be extended, a heat
shrink joint must be used. Ensuring that the con­nection is safely sealed.

TMS installation tape

Installation

Stage 1: Heating cable’s

installation

1) in the surface

Before commencing the installation of the sys­tem, it is required to assess the necessary heat
output per m

2

, as well as calculate the required

spacing of the heating cable.

In order to calculate the required heating cable’s
spacing, apply the following formula:

a-a = S/L

where:

a-a: distances between cables,
S: surface area, for the surface heated with

the heating cable,

L: heating cable’s length.

12

The heating cable layout will depend from
the surface type.

Asphalt surfaces

Stages of works:

• Metal installation tape or mesh is placed on the

compacted (hard core) base, with the heating
cable attached to it – installation tape’s tongues
should be folded so that they would not
straighten up during asphalt rolling

• Power supply conductors (”cold tails”) in

asphalt should be positioned in the protective
metal installation conduit. Alternatively, power
supply conductors can be led out of the area
where asphalt will be poured out

• The 40-50 mm-thick layer of asphalt is laid out

manually – Stage 4

• The asphalt surface is rolled – Stage 4

Cross section of a driveway or road with asphalt surface

40-50 mm-thick

layer of asphalt

Temperature

and moisture sensor
in installation tube

Compacted
base

TM

ELEKTRA TuffTec

heating cable

Metal installation mesh
or ELEKTRA TMS
steel installation tape

Concrete surfaces

Concrete surfaces require epansion joints. Unreinforced
concrete slabs should be divided into expanded areas

of the surface no larger than 9 m

2

, reinforced concrete

agstones – into areas no larger than 35 m

2

. The length
of the heating cables should be selected so that they
would not cross the expansion joints. Only the power
supply conduits (“cold tails”) can cross the expansion
joints. They are to be placed in a metal protective con­duit of the length of approx. 500 mm.

13

Heating Cables

ELEKTRA

ELEKTRA TuffTec

TM

heating cable

Temperature

and moisture sensor

in installation tube

Expansion joint

Compacted
base

Concrete slab
min. 50 mm thick

Cross section of a pavement or driveway

made of concrete slab

Reinforced concrete agstones

Heating cables can be fastened to the reinforce­ment of the ferroconcrete agstones. Alterna­tively, the installation mesh of 100 mm x 100 mm
grid made of Ø 4 mm wire can be applied, which
would facilitate maintaining steady spacing of the
cable, conforming to the calculated values.

ELEKTRA TuffTec

TM

heating cable

Roadway layer

(e.g. resin, quartz)

Reinforcement
of the f

erroconcrete

flagstone

Metal
mesh

Layer of plaster,
e.g. acrylic,
on plastering mesh

Thermal
insulation

Cross section of a suspended loading ramp

Unreinforced concrete surfaces

Stages of works:

• The compacted base is levelled

• ELEKTRA TMS installation tape or installation

mesh are laid on the compacted base, the
heating cable is fastened to them

• The concrete slab works follow – Stage 4

14

Applying thermal insulation layer to ferroconcrete

agstone surfaces exposed to wind operation

from below (ramps, bridges, overpasses) can im­prove the system’s effectiveness.

2) on roofs covered with tar-paper,

roof tiles or bituminous shingles

Fastening cables to roofs’ edges

The grips are attached to the roof’s stretches with
pieces of heat-sealing tar paper glued across the
grips.

Titanium-zinc or copper holders

15

Heating Cables

ELEKTRA

Fastening cables
in roof valleys

ELEKTRA TMS steel installation tape or installation
strips are attached to the roof’s stretches with
pieces of heat-sealing tar paper glued across
the tape or strips.

Downpipes receiving water from roof valleys
require heating:

• internal downpipes at the length of approx. 1 m

• external downpipes at their entire length

ELEKTRA TMS
steel installation tape

Installation strip

16

Gutter holder

Gutter spacing wire

(this method of installation will greatly facilitate cleaning)

Downpipe spacing clip

Downpipe spacing wire

Basic accessories for installation of heating cables
in gutters and downpipes:

17

Heating Cables

ELEKTRA

Stage 2: After the heating

cable has been laid

At this stage, it is necessary to undertake
the following steps:

• Stick into the Warranty Card the self-adhesive

label, positioned on the power supply con­ductor of the heating cable

• In the Warranty Card, prepare a sketch of the

heating cable’s layout positioning

• Feed the power supply conductor of the he-

ating cable into the switchboard

• Perform the measurements of:

– heating wire resistance

– insulation resistance

The measurement results of the heating
core’s resistance should not vary from the
one given on the label value with more than

- 5 % , +1 0 % .

The heating cable insulation’s resistance,
as measured with an appliance of the rated
voltage 1000 V (megaohmmeter), should not
drop below 50 MΩ. Enter the results into the
Warranty Card.

After the surface has been completed, repeat
the measurements to check whether the
heating cable has not been damaged while
conducting works.

18

(brown

or black)

(yellow-green)

Power supply conductor

Ohmmeter

Megaohmmeter

(brown

or black)

(blue)

Heating wire’s resistance measurement

Insulation’s resistance measurement

19

Heating Cables

ELEKTRA

Stage 3: Temperature and

moisture sensor’s
installation:
preparation to
in-surface installation

• Establish the optimal positioning for the tem-

perature and moisture sensor – a place which
would be especially vulnerable to prolonged
low temperatures and increased moisture
deposition (e.g. in a shade or exposed to
wind).

• Feed the protective conduit with the so called

“draw wire” from the planned sensor’s posi­tioning to the switchboard (after the surface
has been completed, the protective conduit
will enable feeding the temperature and
moisture sensor’s wire).

Note:

Fill the spot selected for the sensor’s installa­tion with material to be removed after con­crete or asphalt has been cured (e.g. a wooden
block of 100 x 100 mm and the height equal to

the planned thickness of the nished surface).

!

Note:

The protective conduit should be run in such
a way to enable the future exchange of the tem­perature and moisture sensor, if required.

!

20

In case of a signicant sensor’s distance from

the switchboard, or bending of the protective
conduit, it is necessary to:

• install an additional sealed electric box “on

the way” to the board, or

• install the protective conduit with a twisted

pair screened control cable, min. 3-pair (e.g.
LIYCY-P 3x2x1.5)

– the sensor’s wire with the control cable is

to be connected with a heat shrink connect­ing joint

Stage 4: Finishing surface

works

During execution of the asphalt surface, rst

select the positioning place for the installation
tube, then – after the asphalt has been rolled and
it has cooled down – mount the tube. The space

between the tube and asphalt should be lled

with either concrete or asphalt poured cold, and
the tube should be levelled so that it will be posi­tioned 5 mm below the level of the surface.

For the time of pouring and rolling the asphalt,
the place selected for the positioning of the sen-

sor should be lled with material which – after

the asphalt has cooled down – will be removed
(e.g. a wooden block 10x10x10 cm in size).

Note:

The section of the protective conduit to be laid
in asphalt should be made of a metal pipe, due
to high temperatures present while asphalting.

!

21

Heating Cables

ELEKTRA

Stage 5: Sensor’s installation

1) in-surface temperature

and moisture sensor

The sensor should be installed on the previously
selected and prepared spot. Remove the wooden
block and feed the sensor’s wire with the so
called “draw wire” into the protective conduit

installed before nishing works on the surface.

Under the sensor, the wire excess should be de­posited (min. 300 mm) for the future sensor re­placement, if required.

The sensor should be positioned approx. 5 mm
below the surface level to enable water deposi­tion on the sensor. After the sensor has been le-

velled, ll the vacant space e.g. with concrete.

Ground temperature and moisture sensor ETOG-56T with

installation tube (for soil, concrete agstones, paving

cobbles etc.) can be used for heating control of drive-

ways, trafc routes, etc.

Example of temperature and moisture sensor’s installation

in the surface

installation tube

protective

conduit

5 mm

sensor’s wire laid with
approx. 30 см excess

sensor

ller
e.g. concrete

surface

compacted base
under the surface

22

Stage 6: Temperature

controller’s
installation

The heating cable connection to the domestic
electric circuit should be performed by an authorised
electrician.

The in-controller connection of the:

1. mains,

2. power supply conductors (“cold” cables) of
the heating cable,

3. temperature and moisture sensor

should be executed according to the diagram
included in the temperature controller’s Instructions.

2) on-roof air temperature sensor
and moisture sensor

Position the ETF-744/00 temperature sensor on
the building’s northern wall, in shade.

Position the ETOR-55 moisture sensor between
the cables in the roof’s channel, optimally in the
vicinity of the downpipe.

While selecting the sensors’ positioning,
take into account the necessity of feeding the
wires of both sensors to the controller.

23

Heating Cables

ELEKTRA

Single-phase electric circuit

Connection diagram of ELEKTRA TuffTec™ 30/230V heating cable
with temperature and moisture sensor
and ELEKTRA ETR2G temperature controller

ETR2G

230V

sensor’s wire

heating cable

grey

pink

yellow

white

brown

green

N

NL

PE

L

L

PE

L

N

24

ETR2G

three-phase

electric circuit

heating cable

Three-phase electric circuit

Connection diagram of ELEKTRA TuffTec™ 30/400V heating cable
with temperature and moisture sensor and ELEKTRA ETR2G controller

L3

L2

L1

L3

L2

N

NL

PE

L

L

sensor’s wire

grey

pink

yellow

white

brown

green

25

Heating Cables

ELEKTRA

Single-phase electric circuit

Connection diagram of the heating cable
and temperature and moisture sensor
and ELEKTRA ETR2R controller

ETR2R

230V

heating cable

N

NL

PE

L

L

PE

L

N

yellow

white

brown

green

ETOR-55

ETF-744/99

26

ETR2R

Three-phase electric circuit

Connection diagram of the heating cable
and temperature and moisture sensor
and ELEKTRA ETR2R controller

L3

L2

L1

L3

L2

N

NL

PE

L

L

heating cable

ETOR-55

ETF-744/99

three-phase

electric circuit

27

Heating Cables

ELEKTRA

Anti-shock protection

The electric circuit of the heating cable should be
equipped with a residual current device of the
sensitivity level ∆ ≤ 30 mA.

Warranty

ELEKTRA company grants a 10 year-long
warranty (from the date of purchase) for the
ELEKTRA TuffTec™ heating cables.

28

Warranty Conditions

1. Warranty claims requires:

a. that the heating system has been executed

in full accordance with the Installation In-

structions herein, by a certied electrician,

b. presentation of the properly completed War-

ranty Card,

c. presentation of the proof of purchase of the

heating cable under complaint.

2. The Warranty loses validity if any attempt at

repair has been undertaken by an unauthorised
installer.

3. The Warranty does not cover the damages in-

icted as a result of:

a. mechanical fault,

b. incompatible power supply,

c. lack of adequate overload and differential

protection measures,

d. discord of the domestic heating circuit with

the current regulations in force.

4. Within the Warranty herein, ELEKTRA com-

pany undertakes to bear exclusively the costs
required to cover the necessary repairs to the
heating cable itself, or to exchange the cable.

5. The Warranty covering the purchased commer-

cial goods does not exclude, limit or suspend
other Buyer’s rights resulting from the incom­patibility of the goods purchased with the
agreement of purchase.

Note:

The Warranty claims must be registered with the
Warranty Card and proof of purchase, in the place

of purchase or the ofces of ELEKTRA company.

!

29

ELEKTRA

Heating cables

The Warranty Card must be retained by the Client for the entire warranty period of 10 years.

The Warranty period starts on the date of purchase

PLACE OF INSTALLATION

Address

Zip code City/town

TO BE COMPLETED BY AN INSTALLER

Name and

surname

Electrical authorisation

certicate №

Address E-mail

Zip code City/town

Phone №

Fax

The Warranty claims must be

registered with the Warranty

Card and proof of purchase,

in the place of purchase

or the ofces of ELEKTRA

company