~installation guide ws tw en ver1.4 - max water flow

WARM SURFACES™ Radiant Floor Heating System

INSTALLATION GUIDE TWIN WIRE NON-RETURN TYPE

ISO 9001.2000

UL Listed under UL#1673 CSA C22.2 No.217-M89

UL FILE #E240867 VER 1.4

WARM SURFACES™ INSTALLATION MANUAL VER 1.4

2300 Victoria Avenue, Lachine, Quebec H8S 1Z3 Canada Tel: 514-634-7100 Fax: 514-634-8292 1-888-552-2257 1-888-634-8292

WarmSurfaces.com - 2 -

TABLE OF CONTENTS WELCOME ..................................................................................... 3 SKILL LEVEL .................................................................................. 3 CAUTION....................................................................................... 4 READ CAREFULLY BEFORE STARTING INSTALLATION ...................... 5 LAYOUT PLAN................................................................................ 6 BEFORE INSTALLATION.................................................................. 7 INSTALLING WARM SURFACES™ CABLE SETS.................................. 8 WARNING.................................................................................... 11 VERIFICATION – VERY IMPORTANT .............................................. 12 FLOOR SENSOR INSTALLATION .................................................... 13 THERMOSTAT.............................................................................. 13 THERMOSTAT INSTALLATION....................................................... 14 IMPORTANT NOTICE .................................................................... 15 TILE TIPS .................................................................................... 15 DIRECT MORTAR TECHNIQUE....................................................... 17 Table 1........................................................................................ 19 THERMOSTAT TROUBLE SHOOTING.............................................. 20 ~LIMITED WARRANTY AND LIABILITY~........................................ 21 Product Warranty/Information....................................................... 22 The items you have purchased must include the following:

Warm Surfaces™ Floor Heating Cable Warm Surfaces™ Floor Gauges Warm Surfaces™ wall mounted Thermostat including Floor Probe

You will need the following tools and materials to install the Warm Surfaces™ Floor Heating system. 1) Hot glue gun 2) Metal, electrical outlet box 3) Digital multimeter 4) Megohmmeter 5) Measuring tape 6) Screwdriver & hammer 7) Wood chisels 8) Fish cord 9) Large cardboard sheet 10) Paper and Pencil 11) Builders Square 12) Chalk Snap Line 13) Thin set Self-leveling Mortar 14) Plastic trowel not metal 15) Staple gun 16) Cement float plastic not metal ELECTRICAL REQUIREMENTS 120 V systems require one single pole 20 Amp breaker for each floor cable 240 V systems require one double pole 20 Amp breaker for each floor cable Electrical wire suitable for the system, 12/2 wire with ground 300Vac




WELCOME Thank you for choosing the WARM SURFACES™ floor heating system. This product has been designed to provide warmth to flooring materials such as marble, ceramic and porcelain tile, slate, engineered wood, granite and poured or dimensional stone.

Before using WARM SURFACES™ floor heating system under any floor covering always refer to the floor-covering manufacturer.

WARM SURFACES™ floor heating systems utilize state-of-the-art heating cables, hardware and electrical controls for an economical and long lasting floor heating system.

WARM SURFACES™ is designed for use inside residential and commercial buildings. WARM SURFACES™ floor heating systems are available in cable sets of "120” volt and “240” volt series products. WARM SURFACES™ produces a full range of floor heating cable lengths that may be used in virtually any room and cover virtually any area. WARM SURFACES™ floor heating cable is manufactured using the highest quality materials. NON-RETURN RESISTANCE WIRE

PVC Copper Shield Teflon Resistance Jacket 0 EMF Insulation Wire

SKILL LEVEL WARM SURFACES™ recommends that CERTIFIED or QUALIFIED professionals install any floor heating system. Ask your distributor for a list of recommended installers. Electrical inspection is required during and after system installation. Check with your local electrical inspection department before beginning installation. All installations must be according to local and national electrical codes.




CAUTION DO NOT pull the floor heating wire tight around the floor gauge. DO NOT energize a coiled cable. DO NOT cut or alter the length of the cable. Never use the WARM SURFACES™ floor heating cable for applications other than floor heating. Never use a metal trowel or other tool on the cable. This will damage the floor heating cable. Never install the heating portion of the cable in a wall. Never attempt to repair a damaged cable. Consult your WARM SURFACES™ Representative. It is not recommended to extend the floor heating cable beyond the room in which it originates.

Never install floor-heating cable in an area that will be covered by cabinets, toilets, sinks, bathtubs or shower stalls. Never combine systems of different voltages. Never use spacing less than 1 1/2” between floor-heating cables. Never try to use floor-heating cable to dry a wet floor. THIS SYSTEM IS NOT WATERPROOF. Never use floor-heating cable in an area prone to water infiltration. Never cut or nick the outer insulation of the floor heating wire. Never overlap the floor heating cables. Dangerous overheating will occur. Never overlap the power leads and the heating cable. Dangerous overheating will occur. It is not recommended to install the floor heating cable in a shower stall.




READ CAREFULLY BEFORE STARTING INSTALLATION 1. Verify your cable selection by measuring and determining the square footage of the “heated area”. Do not include areas were cabinets, sinks, shower stalls or closets may be installed. Note: Since the heating cable cannot be cut and that it’s whole length has to be covered by the base mortar. The selected cable should always cover an area equal to or less than that of the heated area excluding the “SAFETY ZONE”. (The safety zone is an area of the room where heating can be modified without compromising the total comfort of the room) See FIGURE 1. 2. Tampering with the length of the cable (cutting the cable) will result in injury and/or fire hazard thus voiding the warranty. 3. It is very important that once the layout of the floor heating cable is complete, we suggest that a drawing or photo be made and kept in your records for future reference. 4. WARM SURFACES™ floor heating system may be used as a primary source of heat. Heat generated from the floor is in direct relation with the area of the heated floor (12 watts /sq ft @ 3” spacing). You should carefully evaluate your heating needs for your region. A separate source of heat may be needed. Note: DO NOT pull the floor heating wire tight against the floor gauge, create a 3” loop. DO NOT press the ears of the gauge into the floor heating wire. 5. WARM SURFACES™ floor heating system is an “electrical appliance” and it should be installed in accordance with local and national electrical codes. Qualified personnel should supervise its installation.




LAYOUT PLAN Before installing the cable, insure that all surfaces on which the heating cable will lie are free from any sharp objects, i.e. nails, screws, staples, splinters, debris or other restrictions that may cut or otherwise damage the heating cable. Using a suitable marker, a square, a chalk line and a straight edge, draw the cable layout directly and accurately onto the sub floor. Refer to HEATED AREA FIGURE 1 for layout details. Carefully consider the location of the “safety zone”, (safety zone is an area of the room where heating can be modified without compromising the total comfort of the room) FIGURE 1. Allow sufficient space along walls and cabinets and around floor drains, toilets and showers. The heating cable must not overlap under any circumstance. Overlapping will create a hot spot and will damage the cable. When you have finished drawing the layout on the sub floor, mark the location of the Warm Surfaces™ floor gauge.

Safety Zone

Heated Area

Temperature Probe

Figure 1




BEFORE INSTALLATION With a digital multimeter measure the resistance of the cable between the two leads, (Black wire and Red wire or Black wire and White wire) see (FIGURE 2). The resistance of each cable should be within 2 percent of the value in Table 1. The measurement should agree with the value marked on the spool Record this value on the warranty page.

If the resistance does not match the resistance of the specific cable you have purchased, please contact your WARM SURFACES™ Representative. With a Megohmmeter measure the insulation resistance between the Black wire and the Green wire. The insulation resistance must not be less than 1000 megohms. Record this value on the warranty page.

Figure 3

Figure 2

Proper knowledge of test equipment is required. Electrical shock may occur.




If you have measured less than 1000 megohms of resistance between the Black and Green wires, Do not connect the cable, contact your WARM SURFACES™ Representative. INSTALLING WARM SURFACES™ CABLE SETS The Warm Surfaces™ Floor Gauge can be stapled to a plywood floor or sub floor. On concrete surfaces the Floor gauge may be attached by means of hot melt glue, self-tapping concrete anchors or equivalent.

It is important to properly uncoil the floor heating cable to prevent twisting. Support the wire spool so it may turn freely while installing the floor heating wire

Figure 4

Figure 5

3” Loop Do not pull cable tight

3” Separation from wire to wall




Cut a hole in the drywall and the sill plate large enough for three wires from the floor heating cable and the floor sensor to pass through. This will be normally 1” diameter. Pull the three cold leads (Green, Black and Red or Green, Black and White wires) from the main spool through a fish hole in the sill plate using fish cords, and then into the junction box. The cable should be pulled until the factory splice between the heating wire and the lead wire is within 6 to 12 inches of the entry point of the wall cavity.

Mark the splice locations on the floor and temporarily set splice aside. Due to the larger thickness of the splice and cold lead, remove approximately ¼” of sub floor material below splice/cold lead areas to eliminate any possible interference with tile. (For wooden sub floors, use utility knife or chisel; for concrete, use appropriate chisel.) Remove all debris after this step to avoid cable damage.

Figure 6

3” Separation Between wire

Cold Leads and Floor sensor wire

Cold Joint




Secure splice and cold lead to floor in recessed areas using Hot melt glue or 2" lengths Warm Surfaces™ Floor Gauge stapled on either side of splice. Insure staples do not penetrate the cable. (Do not staple the cable). Secure starting point of the heating cable with pieces of cable strapping fastened to the floor. (FIGURE 7) Place a cardboard box on the floor to protect the heating wire when kneeling or walking over the heating wire. Slide the floor heating cable under the Warm Surfaces™ Floor Gauge tabs at appropriate intervals and proceed with cable installation following pattern originally drawn on the floor. If the floor heating cable does not fit easily under the tab, bend the tad up to allow the cable to freely slide under the tab. Insure the heating cable is securely fastened at each turn. DO NOT pull the cable tight or crimp the cable tight in the tabs of the Warm Surfaces™ Floor Gauge. (Do not staple the cable).

Figure 7




WARNING DO NOT PULL THE FLOOR HEATING CABLE TIGHT AGAINST THE TABS OF THE WARM SURFACES™ FLOOR GAUGE DURING INSTALLATION, AS THIS WILL CAUSE DAMAGE TO THE CABLE. Always form a 3” loop at each corner on the floor gauge. Refer to Figure 8.

When you reach the half way mark, evaluate remaining area. Cable spacing can be adjusted ONLY in the SAFETY ZONE areas. For cable shortage, consider the “safety zone” areas and omit placing heating cable where it would provide little benefit. For excess cable, spacing can be compressed to a minimum 2-inch pattern in “safety zone” areas (FIGURE 9). To adjust cable, gently remove it from the floor gauge, alter the pattern as required and then re-insert the cable into the floor gauge.

Figure 8

3” Loop

Staple, Screw or Glue

Do not bend tabs tight over wire. Hot glue may be used.




Layout of excess cable in the safety zone area

VERIFICATION – VERY IMPORTANT Before proceeding with covering the floor heating cable with self-leveling cement, insure damage has not occurred during installation. Make sure that no wire is overlapping. With a digital multimeter measure the resistance of the cable between the two leads, (Black wire and Red wire or Black wire and White wire) see FIGURE 2. The resistance of each cable should be within 2 percent of the value in Table 1. Verify that this is the same value as recorded on the warranty sheet. If the resistance does not match the resistance of the specific cable you have installed, you should contact your WARM SURFACES™ Representative. With a Megohmmeter measure the insulation resistance between the Black wire and the Green wire. The insulation resistance must not be less than 1000 megohms. Verify that this is the same value as recorded on the warranty sheet. If there is less than 1000 megohms of resistance between the conductor and the braided shield, Do not connect the cable, you should contact your WARM SURFACES™ Representative.

Figure 9

Safety Zone

End of TW




FLOOR SENSOR INSTALLATION Pull the floor sensor cable, through the sill plate hole and into the junction box. Install the thermostat floor sensor wire at a location where the sensor cable extends into the heated area a minimum of 2.5 ft from a “cold” wall and is centered between two adjacent runs of heating cable. Do not locate the thermostat floor sensor closer than 1” from the heating cable this will cause the floor to heat unevenly. Do not cross or overlap any other cable, as this will cause interference with the thermostat control. FIGURE 10. Also refer to thermostat installation instructions for sensor wire placement. THERMOSTAT A standard thermostat, a voltage adjuster or a switch IS NOT SUITABLE to control the system. Only a Warm Surfaces™ thermostat sold with the system has a GFCI (Ground Fault Circuit Interrupter). Use of any other devise will void the warranty.

Temperature Probe Figure 10

Probe wire




THERMOSTAT INSTALLATION Ensure the supply branch circuit has been disconnected and de-energized. Trim excess length of both supply branch circuit and cold lead cables, as necessary, leaving a minimum of 6" to connect to the thermostat.

Strip ½” of insulation off of each conductor. Connect the Warm Surfaces™ floor heating wires to the thermostat terminals marked “LOAD”. Connect the Green wire from the floor heating cable grounding screw in the junction box. Connect the supply wires to the thermostat terminals marked “LINE”.

Installation of all control wiring devices must be according to manufacturer's instructions. Refer to thermostat installation guide.

Figure 11

Proper knowledge of electrical wiring is required. Electrical shock or fire may occur.




IMPORTANT NOTICE TEST THE COMPLETE SYSTEM PRIOR TO COVERING THE HEATING WIRE. APPLY POWER TO INSURE PROPER FUNCTIONING OF THERMOSTAT AND FLOOR HEATING CABLE BEFORE APPLYING A THIN SET OR SELF-LEVELING MATERIAL. SET THE THERMOSTAT ON HIGH TO INSURE CURRENT FLOW. This test must only by applied for no longer than 5 minutes. Applying power longer than 5 min. will damage the cable. Test the system before applying the self-leveling cement. Test the system after applying the self-leveling cement. Do not fully energize the system until the thin set or self-leveling material has fully cured. Some products require 20 days to fully cure. Consult the material manufacture for cure time. TILE TIPS Refer to the manufacturer's instructions for cure time. This will insure that the heat from the cables does not compromise the setting of the mortar/grout. Cure time is not the same as setting time. To minimize potential tile cracking, it is important that the sub floor on which the tile is to be laid is sufficiently rigid. It may be necessary to apply an under-layment such as backer board and/or mesh and mortar to achieve a solid application surface to insure the floor is stable, smooth and clean. Moisture barriers are used to contain water spills in bathrooms. These barriers are typically a waterproof thin film laid on the floor and any necessary joints will be sealed with an appropriate waterproof adhesive. Moisture barriers are to be used in conjunction with WARM SURFACES™ systems by laying the Warm Surfaces™ Heating Wire on the floor first, covered by a thin set self-leveling mortar. The moisture barrier is then laid over the thin set and the flooring completed in the usual manner.




FLOOR COVERING TECHNIQUE After the Warm Surfaces™ Floor Heating Cable has been laid and the resistance measurements have been made you are now ready to set the tiles on the floor. Verify that power has been removed from the cable. You are now ready to pour the self-leveling cement. In this method, the cable is embedded in a "scratch coat" of Thin Set self-leveling cement, which is allowed to cure prior to setting the tiles. This method will protect the wire during the laying out of the tiles. Thin set is applied uniformly over the entire floor area, including any area not being warmed. Cover the floor with a minimum 1/4” of thin-set. DO NOT TROWEL THE SELF-LEVELING CEMENT. After the cement has cured the resistance values are to be measured again and recorded on the WARRANTY card. Then a thin layer of tile adhesive is applied and the tile is set. Before applying power to the system allow the mortar to fully cure. This may take 3 or 4 weeks. This is not the time allowed to set before applying the tile or ceramic. Consult the manufacturer of the material used.

Sub Floor: Wood or Concrete

Floor CoveringTile or Wood

Toweled Mortar

Self-leveling Cement

Heating Cable

Figure 12

Floor




DIRECT MORTAR TECHNIQUE While it is possible to embed the cable directly in the tile-setting mortar, this method requires significant tile setting experience to ensure a quality installation. Several precautions must be followed not to damage the cable. Always use the flat side of a plastic trowel. Always trowel in the direction of the cable. Never place your bucket of mortar on the cable. Never hit the floor with your trowel. Never remove excess mortar between tiles with a knife or scrapper. Use a wet towel or sponge. Before applying power to the system allow the mortar to fully cure. This may take 3 or 4 weeks. This is not the time allowed to set before applying the tile or ceramic. Consult the manufacturer of the mortar.

Sub Floor: Wood or Concrete

Floor Covering Tile or Wood

Trowelled Mortar

Heating Cable

Figure 13

Floor Gauge




OPERATING TIPS DO NOT ENERGIZE THE WARM SURFACES™ FLOOR HEATING CABLE UNTIL THE CEMENT AND MORTAR HAVE FULLY CURED. THIS MAY TAKE 3 TO 4 WEEKS. When first energized, the WARM SURFACES™ system may take up to 3 hours to fully warm your floor. Energy consumption will vary depending on user preferences and outside temperature, but typically will be about 70% of installed capacity when the system is energized. For example, if a 200-Watt (0.2 kW) system is installed and operated for about 80 hours per week (about half of the time), energy consumption will be about 10 kWh per week (0.2 x 80 x 0.7). At $0.10 per kWh, the weekly energy cost would be approximately $1.00. Note: If used as a secondary source of heat in the room, the heat generated by the WARM SURFACES™ system will be, to some extent, redistributed in the home, thereby offsetting the heat required from the primary space heating source. Avoid placing thick mats or rugs on your heated floor, especially in the area where the floor sensor is located. (Such mats or rugs impede the transfer of heat away from the cables and result in the floor area beneath them being warmer than other areas). The use of bath mats and area rugs is acceptable, but they should be no more than 1/4" thick. Avoid mats with rubber or vinyl type backing, as these may decompose with heat and could stain flooring. Avoid placing floor level furniture (futons, mattresses, etc), which rest directly on the floor, over heated areas. This will again impede the transfer of heat away from the cables.




Table 1 120 Volt 3 W/lnft System Coverage Wattage Resistance

SEPERATION 3” 4” Total Amp. Total ohms Length

TW 025120 25 33 300 2.5 47 100

TW 035120 35 46 420 3.6 33 140

TW 045120 45 60 540 4.5 26 180

TW 055120 55 73 660 5.4 22 220

TW 065120 65 86 780 6.6 18 260

TW 075120 75 100 900 7.5 16 300

TW 085120 85 113 1020 8.6 12 340

TW 095120 95 126 1140 9.5 12 380

TW 107120 107 140 1290 11 11 428

TW 122120 122 160 1464 12 10 488

TW 155120 130 172 1860 15 7 620

240 Volt 3 W/lnft

System Coverage Wattage Resistance

SEPERATION 3” 4” Total Amp. Total ohms Length

TW 050240 50 67 600 2.5 95 200

TW 070240 70 93 840 3.6 66 280

TW 090240 90 120 1080 4.5 53 360

TW 115240 115 153 1380 5.6 43 460

TW 135240 135 180 1620 6.9 34 540

TW 150240 150 200 1800 7.8 33 600

TW 170240 170 226 2040 8.7 27 680

TW 190240 190 253 2280 9.8 24 760

TW 215240 215 286 2580 11 22 860

TW 245240 245 326 2940 12 20 980

TW 310240 310 413 3720 15 15 1240




THERMOSTAT TROUBLE SHOOTING Trouble shooting the GFCI

1. Turn power on: Verify that GFCI trips immediately.

Turn power off.

2. Disconnect Green Wire from the bare copper wire in the junction box. Turn power on: Verify that GFCI trips immediately.

Turn power off.

3. Remove the thermostat. 4. With only the Black wire from the floor heating system connected directly

to the Black line wire and the Green wire connected to the bare copper wire, apply power to the system.

5. With a clamp on current meter that can measure 40 mA. full scale,

measure the current in the Green wire. This current should be less than 3 mA.

E2 error on the display Floor temperature sensor error Verify proper connection of the

floor sensor GFCI LED is lit red Ground fault Reset the ground fault GFCI LED is lit red Leak in the floor cable Make sure that the floor

cement is dry GFCI LED is lit red 240 Vac line is improperly

balanced Voltage difference must not exceed +/-10%

GFCI LED is lit red Leak in the floor sensor Replace the sensor No GFCI Function Supply voltage may be below

105 Vac or over 275Vac Replace thermostat

Thermostat can not maintain program

Electrical noise may reset the thermostat to its default

Heating symbol SSS is shown but does not heat

Floor heating cable is disconnected

Verify wire connections




~LIMITED WARRANTY AND LIABILITY~ Cable warrants to the original purchaser only, that if there are any defects in material or workmanship in any WARM SURFACES™ cable during the first twenty-five (25) years after the date of its purchase, we will refund the purchase price of the cable, not including any labor or other installation costs. Our obligation to refund the purchase price described above is conditional upon (a) the installation of your cable conforming to the specifications set forth in our installation manual and (b) the cable not having been damaged by mechanical or electrical activities unrelated to the operation of the cable. A refund of your purchase price as described above shall be your sole and exclusive remedy for a breach of this warranty. This limited warranty does not cover any costs relating to the repair or replacement of any cable. K&L Cable Division of 6060099 Canada Inc. assumes no responsibility under this warranty for any damage to the product caused by any trades people, or visitor on the job site, or damage caused as a result of post installation work. We shall not be liable for any incidental, special or consequential damages as a result of any breach of this warranty or otherwise, whether or not caused by negligence. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. No affirmation of fact or promise made by us, by words or action, shall constitute a warranty. Any implied warranty of merchantability or fitness for particular purpose that may arise in connection with the sale of this product shall be limited in duration to twenty-five (25) years from the date of purchase. We disclaim all other implied warranties, unless we are prohibited by law from doing so, in which case all such implied warranties shall expire at the earliest time permitted by applicable law. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. If the repair of the product is not feasible, K&L Cable will replace the Product or refund the original cost of the Product. To obtain a refund under this warranty, please send a description of the defect and proof of purchase, postage paid, to WARM SURFACES™ at the address noted herein. @2006 WARM SURFACES™.




Product Warranty/Information Keep the original for your records

Warranty is not valid unless warranty is returned Mail or fax to:

1-888-634-8292 or 1-514-634-8292

Heating Wire type: ___TW__________________

Resistance Measurement Factory measurement: _______________________

Insulation Resistance Measurement

Factory measurement: _______________________ ------------------------------------- Cut here-------------------------------------

Heating Wire type: ___TW___________________________________________ Name: _____________________________________________________________ Address: ___________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ City: _______________________________________________________________ State /Province: _____________________________________________________ Zip/Postal Code: _____________________________________________________ Date of Purchase: ____________________________________________________ Purchased from: _____________________________________________________ Location: ___________________________________________________________

Resistance Measurement Before installation: ___________________After installation: __________________

Insulation Resistance Measurement Before installation: ___________________After installation: __________________

Floor Finishing Type of sub floor: ___________________Type of mortar used: _______________ Type of tile used: ___________________

Type of room Kitchen ___ Bathroom ___ Rec. Room ___ Other Specify: ________________

~installation guide ws tw en ver1.4 - max water flow

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