Infloor Electric Cable 386 User Manual

Electric Cable

Installation Manual

Series 386 & 387

If you have any questions, please call 1-800-608-0562

Please be aware local codes may require this product and/or the thermostatic control to be installed or connected by an electrician.

Assembled in the

USA

www.infloor.com

Read this Manual BEFORE using this equipment. Failure to read and follow all safety and use information can result

in death, serious personal injury, property damage, or damage to the equipment.

Keep this Manual for future reference.

Infloor Electric Cable is a simple, economical way to warm any floor, and provide years of lasting comfort. This instruction manual provides complete details, suggestions, 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!

Specifications for Infloor Electric Cable:

Infloor Electric Cable is a complete heating cable consisting of a series resistance heating cable and a power lead for connection to the electric power supply. The heating cable cannot be cut to fit.

Voltages: 120 VAC, 240 VAC, 1-phase Watts: 10 W/sqft (34 Btu/h/sqft) when spaced 3-1/2" inches on center, up to 15 W/sqft

(51 Btu/h/sqft) when spaced 2-1/2" inches on center (see Table 2)

Maximum circuit load: 15 amps Maximum circuit overload protection: 20 amp breaker GFCI: (Ground Fault Circuit Interrupter) required for each circuit (included in the Infloor control) Listing: UL Listed for U.S. and Canada under UL 1673 and CAN/CSA C22.2 No. 130.2-93,

File No. E185866 Application: Indoor floor heating only (-X on the nameplate label indicates CUL Listing for

this application). Suitable for installation in a shower area (see Step 3.19 for restrictions) (-W on the nameplate label indicates CUL Listing for Wet Location in Canada per Canadian Electrical Code, Part I (CEC)).

Embedded in polymer-modified cement based mortar only (see Appendix 1).

Minimum bend radius: 1 inch Maximum exposure temperature:

(continuous and storage) 194ºF (90ºC) Minimum installation temperature: 50ºF (10ºC)

Factor y Splice

Heating Wire

End Splice

Power Lead

Installation must be performed by qualified persons, in accordance with local codes, ANSI/ NFPA 70 (NEC Article 424) and CEC Part 1 Section 62 where applicable. Prior to installation, please consult the local codes in order to understand what is acceptable. To the extent this information is not consistent with local codes, the local codes should be followed. However, electrical wiring is required from a circuit breaker or other electrical circuit to the control. It is recommended that an electrician perform these installation steps. Please be aware local codes may require this product and/or the control to be installed by an electrician.

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Expected floor temperature

Heating performance is never guaranteed. The floor temperature attainable is dependent on how well the floor is insulated, the temperature of the floor before start up, and the overall thermal drain of the floor mass. Insulation is required for best performance. Refer to Phase 6 for important design considerations.

These are the three most common installations:

Wood framing: 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 warmer than they would otherwise be.

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 perhaps 15°F warmer than they would otherwise be.

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 perhaps 10°–15°F 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 7: Install Insulation” on page 20.

Table of Contents

Important Safety Information .....................3

Phase 1 - Preparations ..............................5

Phase 2 - Electrical Rough-in ....................9

Phase 3 - Install the Cables .....................11

Phase 4 - Finish Wiring ............................17

Phase 5 - Control Installation ..................18

Phase 6 - Install the Floor Coverings .......19

Phase 7 - Install Insulation .......................20

Appendi ces ..............................................22

Troubleshooting .......................................33

Warranty ................................................... 35

Important Safety Information

This is a safety-alert symbol. The safety alert symbol is shown alone or used with a signal word (DANGER, WARNING, or CAUTION), a pictorial and/or a safety message to identify hazards.

When you see this symbol alone or with a signal word on your equipment or in this Manual, be alert to the potential for death or serious personal injury.

This pictorial alerts you to electricity, electrocution, and shock hazards.

This symbol identifies hazards which, if not avoided, could result in death or serious injury.

This symbol identifies hazards which, if not avoided, could result in minor or moderate injury.

This symbol identifies practices, actions, or failure to act which could result in property damage or damage to the equipment.

Table 1

As with any electrical product, care should be taken to guard against the potential risk of fire, electric shock, and injury to persons. The following cautions must be observed:

NEVER install Infloor Electric Cable under carpet, wood, vinyl, or other non-masonry flooring without embedding it in thin-set, thick-set, or self-leveling mortar.

NEVER install Infloor Electric Cable in adhesives or glues intended for vinyl tile or other laminate flooring, or in pre-mix mortars. It must be embedded in polymer modified, cement based mortar.

NEVER cut the heating wire. Doing so will cause dangerous overheating and will void the warranty. The power lead may be cut shorter if necessary, but never remove completely from the heating wire.

NEVER bang a trowel or other tool on the heating wire. Be careful not to nick, cut, or pinch the wire causing it to be damaged.

NEVER use nails, staples, or similar to fasten the heating wire to the floor.

NEVER attempt to repair a damaged heating wire, splice, or power lead using unauthorized parts. Use only factory authorized repair parts and methods.

NEVER splice one heating wire to another heating wire to make it longer. Multiple Infloor Electric Cable power leads must be connected in parallel in a junction box or to the thermostat.

NEVER install one wire on top of another or overlap the heating wire on itself. This will cause dangerous overheating.

NEVER forget to install the floor sensor included with the thermostat.

NO!

NEVER bang a trowel or other tool on the heating cable.

NEVER install Infloor Electric Cable in any walls, or over walls or partitions that extend to the ceiling.

NEVER install wires under cabinets or other built-ins having no floor clearance, or in small closets. Excessive heat will build up in these confined spaces, and the wire can be damaged by fasteners (nails, screws, etc.) used to install built-ins.

NEVER remove the nameplate label from the power leads. Make sure it is viewable for inspection later.

NEVER extend the heating wire beyond the room or area in which it originates.

NEVER allow a power lead or sensor wire to cross over or under a heating cable. Damage could result.

ALWAYS completely embed the heating wire and factory splices in the floor mortar.

ALWAYS maintain a minimum of 2.5" spacing between heating wires. ALWAYS pay close attention to voltage and amperage requirements

of the breaker, the thermostat, and the Infloor Electric Cable. For instance, do not supply 240 VAC power to 120 VAC Infloor Electric Cable as damage will result.

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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.

ALWAYS!

ALWAYS test the wire before and after installation.

ALWAYS make sure all electrical work is done by qualified persons in accordance with local building and electrical codes, Section 62 of the Canadian Electrical Code (CEC) Part I, and the National Electrical Code (NEC), especially Article 424.

ALWAYS use copper only as supply conductors to the thermostat. Do not use aluminum. ALWAYS seek help if a problem arises. If ever in doubt about the correct installation proce-

dure to follow, or if the product appears to be damaged, the factory must be called before proceeding with the installation.

Installation must be performed by qualified personnel, in accordance with local codes and standards. A licensed electrician is recommended.

Phase 1 - Preparations

Before installing Infloor Electric Cable, make sure to fully inspect the products and carefully plan the site.

Items Needed

Materials:

• Infloor Electric Cable system

• Wire Strap (provided with the cable)

• Infloor

• Infloor Relay control (if required)

•

• Infloor Sensor Tube p/n 29011

• Junction electrical box (if required, see Step 2.2)

•

• Flexible or rigid conduit (if required, see Step 2.4, must be UL Listed and proper size)

• 12-guage or 14-guage electrical wiring cable (UL Listed, see Step 2.1)

• Nail plate

thermostat with floor sensor

Control electrical box (UL Listed, extra deep, see control instructions for size and type required)

Wire nuts (if a junction electric box is required, see Step 2.2, must be UL Listed and proper size)

Too l s:

•

Digital multi-meter (for ohms testing; must read up to 20,000 ohms (Ω) to measure sensor)

• Drill with 1/2" and 3/4" bits

• Hammer and chisel

• Got glue gun and hot glue (craft grade)

• Wire strippers

• Phillips screwdriver

• Fish tape

• Hole saw

• Floor covering installation tools

Floor sensor is included in the thermostat packaging. This must be installed in the floor with the cable.

Table 2 - Cable sizes

Please check the product label for exact ratings. This table is for reference only.

120 VAC

Model

Number

38630 8 10 12 39 1.0 108 - 134 38631 38632 38633 38634 38635 38636 38637 38638 38639 38640 38641 38642 38643 84 100 120 391 10.0 10 - 13

240 VAC

Model

Number

38730 17 20 24 78 1.0 217 - 267 38731 38732 38733 38734 38735 38736 38737 38738 38739 38740 38741 38742 38743

Total Sq. ft.

2.5" Spacing

14.4 wat ts/ft

Total Sq. ft.

3" Spacing

12 watts /ft

10.3 w atts/ft

Total Sq. ft.

3.5" Spacing

Wire

Length

(ft.)

Amp

Draw

Resistance

13 15 18 59 1.5 72 - 89 17 20 24 78 2.0 53 - 66 21 25 30 98 2.5 42 - 52 25 30 36 117 3.0 33 - 42 29 35 42 137 3.5 29 - 37 34 40 48 157 4.0 25 - 32 38 45 54 176 4.5 22 - 28 42 50 60 196 5.0 20 - 26 51 60 72 235 6.0 16 - 21 59 70 84 274 7.0 14 - 19 67 80 96 313 8.0 12 - 16 76 90 108 352 9.0 11 - 14

Total Sq. ft.

2.5" Spacing 15 watts /ft

Total Sq. ft.

3" Spacing

12 watts /ft

Total Sq. ft.

3.5" Spacing 10 watts/f t

Wire

Length

(ft.)

Amp

Draw

Resistance

25 30 36 117 1.5 143 - 176 34 40 48 157 2.0 107 - 132 42 50 60 196 2.5 84 - 104 51 60 72 235 3.0 67 - 83 59 70 84 274 3.5 59 - 73 67 80 96 313 4.0 50 - 63 76 90 108 352 4.5 45 - 56

84 100 120 391 5.0 40 - 50 101 120 144 470 6.0 33 - 42 118 140 168 548 7.0 29 - 37 135 160 192 626 8.0 24 - 31 151 180 216 704 9.0 22 - 28 168 200 240 783 10.0 20 - 26

(ohm s)

It is important to select the proper size cable for the given area. Infloor Electric Cable cannot be cut shorter in order to fit a given area. Doing so will damage the heating wire and prevent the system from working.

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To prevent the risk of personal injury and/or death, make sure power is not applied to the product until it is fully installed and ready for final testing. All work must be done with power turned off to the circuit being worked on.

STEP 1.1

Remove the Infloor Electric Cable, Infloor thermostat, and Infloor sensor from their packages. Inspect them for any visible damage. Verify everything is the correct size and type according to the plan and the order. Do not attempt to install a damaged product.

STEP 1.2

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 (Table 4). If installing more than one cable, do this for each of them.

STEP 1.3

Use a digital multi-meter set to the 200Ω or 2000Ω (2kΩ) range to measure the resistance between the conductors of the cable power leads. Record these resistances in Table 4 under “Out of the box before installation”. The resistance should measure within the resistance range on the nameplate label. If it is a little high or low, it may be due to air temperatures or meter calibration. Consult the factory if in doubt.

Measure the resistance between either of the white or black leads and ground lead. This measurement should be “open”, usually indicated by an “OL” or a “I”. This is the same as displayed when the test leads are not touching anything.

If there is any change in the reading, record this information and contact the factory before continuing. This could indicate damage, test lead problems, or a number of other issues. Try “pinning” the test leads to the cable lead wires against a hard non-metal surface if the readings continue to fluctuate.

Change the meter to the 20,000 ohms (20 kΩ) range. Measure between the lead wires of the Infloor sensor. This resistance varies according to the temperature sensed. Table 3 provides approximate resistance-to-temperature values for reference.

Ground Lead

White or Blue Lead

200 ohm

setting

Black Lead

White or Blue Lead

Black Lead

White or Blue Lead

Table 3 - Floor Sensor Resistance Values

Temperature Typical Values

55°F (13°C) 17,000 ohms 65°F (18°C) 13,000 ohms 75°F (24°C) 10,000 ohms

85°F (29°C) 8,000 ohms

Black Lead

Table 4 - Cable and Sensor Resistance Log

Cable 1Cable 2Cable 3

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 white (black to blue for 240VAC) 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!

INSTALLATION NOTES

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Phase 2 - Electrical Rough-in

STEP 2.1: Circuit Breaker (Overcurrent Protection)

Infloor Electric Cable must be protected against overload by a circuit breaker. GFCI type (ground fault circuit interrupter) or AFCI type (arc-fault circuit interrupter) breakers may be used if desired, but are not necessary when using Infloor controls with integral GFCI.

The rating of the breaker (see Table 5) is determined by the amp draw of the heating cables. Add the amp ratings of all cables to be connected to the Infloor control (see Table 2 or the Nameplate Label on the cable). If the total is less than 12 amps, use a 15 or 20 Amp breaker (preference is 15 A). If the total is between 12 and 15 amps, use a 20 Amp breaker. If the total is over 15 A, another circuit will be required with its own breaker and Infloor control.

It may be possible to tap into an existing circuit as long as there is adequate capacity for the cables(s) and any additional appliance, such as a hair dryer or vacuum cleaner. Avoid circuits which have lighting, motors, exhaust fans, or hot tub pumps due to possible interference.

STEP 2.2:

Table 5

Circuit Breakers and Supply Wire

Cable(s) Supply Wire Breaker VAC total amps (AWG)* qty type** rating 120 up to 12 amps 14 1 SP 15 or 20 A 120 up to 15 amps 12 1 SP 20 A 240 up to 12 amps 14 1 DP 15 or 20 A 240 up to 15 amps 12 1 DP 20 A

* Recommended only. Follow local codes for wire gauge size. ** SP= single-pole, DP=double-pole

Install Electrical Boxes

Infloor Thermostat:

Install an extra-deep electrical box for the Infloor Thermostat. Follow the instructions included with the thermostat for complete information on location and wiring.

Infloor Relay:

Install an extra-deep electrical box for any Infloor Relay(s). The Infloor Relay is used when more than 15 amps must be controlled by one Infloor Thermostat. Follow the instructions included with the Infloor Relay for complete information on location and wiring.

Junction Boxes:

If a cable is to be located so its power lead is not long enough to reach the Infloor thermostat or Infloor Relay directly, a junction box must be installed. Do not attempt to make a connection to other wiring without a junction box. Use a standard junction box with a cover, mounting it below the subfloor, in the attic, in the wall, or in another location easily accessible after all coverings are complete. If the Infloor sensor wire is not long enough to reach the Infloor thermostat directly, it may be extended. A junction box may be required by local code to make this connection. Follow the installation instructions included with the Infloor control for details.

For construction with an existing wall or where the wall is covered, cut the necessary openings to mount the electrical boxes listed above. Wait to install the boxes until all wiring is fed into these locations to make it easier to pull the wire.

STEP 2.3: Bottom Plate Work

Drill or chisel holes at the bottom plate as indicated. One hole is for routing the power lead conduit and the other is for the thermostat sensor. These holes should be directly below the electrical box(es).

Power lead

conduit

Wire

Clip

Sensor wire

If going in to an existing wall, cut out

Power

lead

Sensor wire

dry wall and chisel out bottom plate to route wires to control.

STEP 2.4: Install Power Lead Conduit and Thermostat Sensor

Power Lead Conduit:

The shielded power lead can be installed with or without electrical conduit (recommended for added protection against nails or screws) depending on code requirements. Remove one of the knock-outs in the electrical box to route the power lead. If electrical conduit is not required by code, install a wire collar to secure the power leads where they enter the box. If conduit is required by code, install 1/2" (minimum) conduit from the bottom plate up to the electrical box. For multiple power leads (multiple cables) install 3/4" conduit.

Infloor Thermostat Sensor:

The Infloor sensor should be installed in a plastic sensor tube (P/N 29011) or electrical conduit. Sensor tube or conduit is recommended for added protection against nails or screws. Do not place the sensor in the same conduit as the power leads to avoid possible interference. Open a separate knock-out in the bottom of the thermostat box. Feed the sensor tube or conduit through the knock-out, down through the cut-out in the bottom plate, and out into the floor where the heating cable will be installed. Feed the thermostat sensor down the sensor tube.

STEP 2.5: Rough-in Wiring:

Install appropriate 12 or 14 AWG electrical wire from the circuit breaker or branch circuit source to the Infloor Thermostat electrical box (and Infloor Relay box(es) if needed) following all codes, see Table 5.

If Infloor Relay(s) are used, feed appropriate wire (see Infloor Relay installation manual for size and type) between the Infloor Relay(s) and the Infloor thermostat.

See Infloor Relay instructions for details of wire size and type.

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Phase 3 - Install the Cables

STEP 3.1: Floor Cleaning

The floor must be completely swept of all debris including all nails, dirt, wood, and other construction debris. Make absolutely sure there are no objects on the floor which might damage the wire.

Wet mop the floor at least twice to ensure there is no dirt or dust. This will allow proper bonding of the mortar and proper stick of any adhesives or double-sided tape used later.

STEP 3.2: Outline the Heated Area

Use a marker to outline the area where the heating cable will be installed. This includes any cabinet base or fixture not already installed, across doorways, next to toilets, etc.

Cabinet vanities: Draw the border right up to the toe-kick. Tubs and shower entries: Draw the border about 3" from the edge of the tub or shower. Walls: Draw the border about 3" from the wall. If required to help the cable fit better, it may

be drawn 4" to 6" from the wall since people do not generally stand this close to a wall anyway. It may also be drawn closer, but be careful that the cable will not be placed under any trimwork.

• Keep the cable at least 6" from wax toilet rings.

• Do not run the cable under cabinets or fixtures that have no clearance under them.

•

Avoid running the cable into a small closet or pantry. The heat cannot escape and things can be laid on the floor, blocking the heat and potentially overheating and causing a fire hazard.

STEP 3.3 Make Sure the Cable Fits

Check the cable size to ensure it will fit inside the Heated Area at the selected wire spacing.

Remember the heating cable length CANNOT be cut to fit. It must be kept its original length and fully embedded in the mortar in the floor. Any modification or mis-use of the heating cable will void the warranty and cause potential shock or fire hazard.

STEP 3.4 Decide the Layout

Decide which direction the cables will run on the floor for the easiest coverage. Refer to the sample layouts in this manual for assistance. Depending on the shape of the area, it may help to think of it in terms of several smaller areas.

+ 25 hidden pages

Infloor Electric Cable 386 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual