Classic Mats Installation Manual 1
Classic Mats WarmTouch Classic Mats are the ideal Electric floor warming systems, designed by DomoTecK, for installation under tile, stone or marble. WarmTouch Classic Mats are easy and simple to install. The warming cable has a Twin-conductor which requires only one connection point to the electric systems; allowing you to start the mat near the control location and end it at any desirable point in the room. The warming cable is durable and screened from beginning to end to thoroughly protect the heating element and provide an optimal level of safety. The mats are only 1/8 thick to minimize any changes floor elevation,and they are feature an absorbent, textile mesh that simplifies the mat installation and perfectly integrates into the floor cross-section. The Mats are also produced with adhesive strips and are sprayed from edge to edge with a bonding agent to securely adhere the mat to the substrate. WarmTouch Classic Mats are perfectly suited for installation under tile, stone, and marble, but are versatile enough to warm other approved floor coverings such as floating wood, laminates, linoleum, and wall-to-wall carpeting as well. WarmTouch Classic Mats should be embedded in latex-modified thin-set mortar for tile and stone warming applications. When installing other floor coverings suitable for use with under floor warming systems (i.e. floating wood, laminates, linoleum, or wall-to wall carpeting) a 1/2 of self-leveling concrete should be used to cover the Classic Mats before laying the floor covering. This 1/2 of self-leveling concrete protects the warming elements, provides a smooth & level surface to lay the flooring, assures optimal heat distribution, and more efficient operation. WarmTouch Technical Data: Mat Output 15 W/Sqft Cable Output 3 W/Linear Ft Voltage 120V AC / 240V AC / 60Hz Wire Thickness 1/8 Protection Means GFCI in accordance to NEC One side connection-twin Conductor Base Material White textile mesh Cable Color Green Wire Spacing 2.5 Supply Lead Length 13Ft WarmTouch Classic Mats can be installed by a professional installer, and should be connected to the building wiring system by a licensed electrician. Our instruction manual will walk you through the complete process of installing WarmTouch Classic Mats. For any questions or needs during the installation process please call our Technical Support at 1-800-959-WARM (9276) Copyright 2007 All Rights Reserved 2
TABLE OF CONTENT WarmTouch Classic Mats Features 2 General Instructions 4 Planning The Installation 5 Electrical Preparation 6-7 Temperature & Time Control 8 Resistance Testing & Warranty Documentation 9 Customizing the WarmTouch Heating Mat 10 Step by Step installation Procedures 11-14 Troubleshooting 15 About DomoTecK 16 3
GENERAL INSTRUCTIONS The instructions in this manual must be followed when preparing and installing the WarmTouch Floor Warming System. This manual and the installation layout should be made available to all installers and the electrician working on the job. Both should then be turned over to the homeowner after the installation is complete..k. Heating Systems, Inc. 587 N. Edge959-WARM fa787-0572 Maintenance WarmTouch Classic Mats have no moving parts and they are completely maintenance-free. To assure the highest level of safety and continued operation, it is imperative that the GFCI protecting the WarmTouch System be tested monthly. Some thermostat models incorporate GFCI protection into the thermostat. Other thermostat models do not. If the floor warming system is connected to a GFCI protected circuit, a thermostat WITHOUT a GFCI should be used. The use of two GFCIs can cause nuisance tripping of the GFCI breaker at the panel or the internal GFCI in the thermostat, which is usually indicated by a red light or display on the LCD screen. If either GFCI trips, it will prevent the floor warming system from operating. Sub-Floors and Floor Coverings WarmTouch Classic Mats may be installed directly over substrates such as concrete, backer boards, selfleveling cement, and plywood in accordance with all TCA guidelines. ALL materials in direct contact with the heating element MUST be rated to withstand 180 degrees Fahrenheit. Special consideration WarmTouch Classic Mats will be most effective and efficient if installed over a well-insulated substrate (i.e. plywood, polystyrene, insulated reflective foil, etc.). Insulation will minimize heat loss into the concrete slab allowing the heat to transfer to the surface more quickly. WarmTouch Classic Mats is specifically designed for use under tile and stone floor coverings. However, it can also effectively warm linoleum, laminates, wall-to-wall carpeting, and other floor coverings suitable for use with electric radiant floor-warming systems when covered by a ½ layer of self-leveling cement. If installing WarmTouch for use under one of these alternate flooring surfaces, we recommend setting the maximum floor surface temperature to no more than 82 F. Consult your DomoTecK Sales Representative to learn more about our Warmth4You Under Wood and Warmth4You Under Carpet floor-warming systems, specifically intended for use under floating laminate/ engineered wood floors and wall-to-wall carpeting. Call our Technical Support Hotline at 1-800-959-WARM (9276) if you need answers to installation questions, need help solving a problem, or believe that the mat got damaged during installation. IMPORTANT! FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL MAY VOID THE HOMEOWNER S WARRANTY ON THE FLOOR-WARMING SYSTEM 4
PLANING THE INSTALLATION Before laying the WarmTouch floor-warming system, review the installation layout and verify that all dimensions match the field dimensions. If you are inexperienced with electric radiant heating systems, it may be helpful to chalk the mat installation layout on the sub-floor prior to customizing the mats. The installation plan should include the following: 1. Placement, direction, and dimensions of the WarmTouch Heating Mats 2. The starting and ending points of each mat 3. The location of the thermostat or other suitable control 4. The location of the floor sensor If you don t have an installation layout, call DomoTecK customer support and get a FREE installation layout for your project. IMPORTANT! The installation plan for each area should be attached to this manual and be provided to the homeowner when the installation is complete. The homeowner will need to reference this installation layout if system trouble-shooting is ever required or future renovations are going to take place in the room. DO IMPORTANT INSTALLATION CONSIDERATION 1. Clean the floor of all debris before placing the mat on the floor. Make sure there are no 2. protruding objects (nails, staples, etc.) on the sub-floor that could damage the heating element. 3. Measure and record mat resistance, and test for shorts as per instructions throughout the installation. 4. Use mats that have the same heat output. For example, ALL mats should be 15 watts/sqft. 5. Make sure all components of the system are rated for the same Voltage (120V OR 240V). 6. Have all electrical work completed by a professional electrician in accordance with all local and national codes. 7. Connect WarmTouch to a Dedicated Circuit. DON T 1. DON T use your floor warming system to dry or cure your flooring installation. Allow the installation to dry naturally and completely before allowing your floor warming system to operate. DON T 2. DON T shorten the heating mat and DON T cut the heating wire. 3. DON T drop or bang any tools on the heating wires with any sharp objects. 4. DON T install any fasteners such as nails, screws, through any area covered by the WarmTouch mat. 5. DON T install WarmTouch under cabinets, built-in appliances, etc. to avoid excessive heat from building up in those areas. 6. DON T install mats over expansion joints. 7. DON T install WarmTouch in walls. 8. DON T install WarmTouch in showers. 9. DON T overlap mats or allow any wires to cross or touch each other. 10. DON T crimp the heating wire while customizing the mat. 11. DON T place area or throw rugs thicker that ½ over the heated area to avoid excessive build-up of heat in these areas. 12. DON T attempt to repair the heating wire with out the proper instructions and repair kit (obtained from your distributor or DK Heating Systems). 13. DON T forget to install the floor-sensor if you are installing a thermostat. 14. DON T install WarmTouch in glues other than cement-based tile-setting mortars. 5
ELECTRICAL PREPARATION All Electrical Connections for the WarmTouch Floor-Warming System and Controls should be done by a Professional Electrician in accordance with all Local and National Electrical Codes. WarmTouch Floor-Warming System Typical Electrical Rough-In 1. A deep, 2 1/8 X 4 single-gang junction box OR a roomier 4 X 4 double-gang box should be provided by the electrician for the thermostat connections. Size and depth of the junction box should be determined by the electrician to accommodate the brand and model of the control provided with the floor warming system. Some brands/models may require the use of a mud plate to reduce the face of the junction box and accommodate the control properly. 2. Two conduits should be run down from the junction box. A. The first conduit, intended for the cold leads from the mat(s), should be ¾ and must be run from the junction box down to floor level. A plastic bushing should be used where the cold leads enter the conduit to protect the wires. The cold leads can be described as low resistance power supply to the heating elements with no heating capabilities. B. The second conduit, intended for the floor sensor, can be a ½ conduit. This ½ conduit should be run from the junction box down to floor level. THE SENSOR WIRE SHOULD NOT BE PLACED IN THE SAME CONDUIT AS THE COLD LEADS. Floor Sensor Placement The floor sensor should be installed after the heating mat has been secured to the underlayment, but BEFORE it is covered with any mortar. Make sure to place the sensor between the heating element wires without crossing or touching any of the element wires as described in the Step-By-Step Installation Procedures. If a sensor was not placed in between the heating elements BEFORE the tile or self-leveling cement was laid, THE SENSOR MAY BE PLACED IN THE GROUT JOINTS between the tiles. See the Trouble-Shooting Section of this Manual Entitled Placing a Sensor in a Grout Joint. If the grout joints are not large enough, please call DomoTecK s Representative at 1-800-959-9276 for further instructions. 6
Extending the Leads The cold leads extend approximately 12-13 from the mat. Since the cold lead(s) cannot be spliced in the floor, the mat should be laid in a pattern that allows the cold lead(s) to run directly to the junction box without crossing or touching any element wires. However, if the cold lead(s) need to be extended, an additional accessible junction box may be installed in the lower portion of a nearby wall, an accessible crawl space, or an accessible basement ceiling. ALL electrical extensions and connections must be done in accordance with all NEC, State, and Local Electrical Codes. The Gage of the extension wire(s) used should be determined by the electrician to accommodate the amperage of the mat(s) being installed. IMPORTANT! Inaccessible extensions or splices are not permitted. Multiple Mat Installations If the project requires more than 1 WarmTouch mat to be connected to the same control, the cold leads from the mats should be connected IN PARALLEL (NEVER IN SERIES) through an additional junction box and extended through the conduit to the thermostat junction box. The Gage of the extension wires used should be determined by the electrician to accommodate the amperage of the mats being installed. (See Section below labeled Use of a Contactor and Separate GFCI for further details.) Use of a Contactor and Separate GFCI (For Multiple Mat Installations) IMPORTANT! Most floor warming thermostats are rated for 15-16 Amps. Some thermostats are equipped with an internal GFCI, others are not. These specifications vary by brand and model. Please review the insert provided with your control to verify the control specifications and review the installation design/ electrical specifications of the floor warming system to determine the necessary electrical requirements prior to preparing the wiring accommodations. If you are missing the manufacturer's instruction/ wiring information, please call our technical support at 1-800-959-9276. If the total amperage of a multiple mat system exceeds 15 Amps: 1. The WarmTouch mats and controls should be connected through a definite purpose contactor (supplied by your electrical contractor) in accordance with all NEC and local electrical codes. If either GFCI trips, it will prevent the floor warming system from operating. Do not use two GFCI devices in the same circuit. Use a GFCI Breaker capable of handling the total load in accordance with NEC and local codes. OPTIONAL: To eliminate the need for a contactor, the installation layout may be designed to split the area into different zones. Each zone can be controlled by a separate thermostat or by links that are connected to one Master Thermostat as described in the Temperature and Time Control section of this manual. Call DomoTecK s customer support at 1-800-959-WARM(9276) to discuss further details about your project. 2. The use of two GFCIs can cause nuisance tripping of the GFCI breaker at the panel or the internal GFCI in the thermostat, which is usually indicated by a red light or display on the LCD screen. 7
Temperature and Time Control OPTION 1 Programmable Thermostat models provide the most versatility and flexibility to adapt the floor temperature to meet all of the homeowners needs at any given time - AUTOMATICALLY. This model allows the homeowner to digitally set two desired floor temperature settings into the thermostat. Programs can be set to establish the desired times and temperature for each weekday individually or weekdays vs. weekends. Vacation mode can also be used to temporarily cease operation for extended periods of time. OPTION 2 Basic (Non-Programmable) Thermostat models allow the homeowner to manually adjust the desired floor temperature with a dial or a digital LCD screen. A floor sensor is connected to the thermostat and placed in the heated area under the flooring surface in between two of the heating element wires. The thermostat operates as necessary to maintain the desired floor temperature when set to the ON position. IMPORTANT! Programmable and Basic Thermostat models MAY or MAY NOT be equipped with an internal GFCI. Please verify the features of your thermostat prior to completing the electrical set-up. ALL systems MUST be GFCI protected by a local GFCI in the thermostat OR by a GFCI breaker at the panel of the home. OPTION 3 Master and Link Units are the most versatile and convenient control option to operate multiple floor warming systems throughout one home or within a very large living space. One Master Control incorporates a floor sensor that is connected to the back of the Master unit. This unit has all of the same Programmable Thermostat features described in Option 1 above except it actually allows the homeowner to operate up to 10 floor-warming systems at one time! Link units are placed in each room or area to provide a manual ON//OFF switch and GFCI protection. The links are then individually connected back to the Master Control. If the homeowner would like to temporarily exclude any given area from the program, it is as easy as switching the link to the OFF/Standby position. OPTION 4 Integration into Home Automation WarmTouch Classic can also be integrated into the home automation system for the highest level of comfort and energy-saving efficiency. Speak with your Home Automation Specialist to see if this is a feasible option for you. DomoTecK s new Thermostat Advantages DomoTecK s control units consist of LCD and an energy unit to which the line voltage and heating element are both connected. The electrical source to the energy unit should originate from a standard US type GFCI. The advantage of our system is that the LCD is a very low voltage only 5 V - while the high voltage unit is installed in a junction box and is positioned as close as possible to the heating element. The separation between the LCD and the energy unit allows the energy unit to be installed in a remote and hidden area. In as much as the energy unit is very quiet in operation when compared to line voltage thermostats, there is little chance of the home owner being disturbed by any noise created by the energy unit's relay when using this type of installation. This separation gives the highest level of safety even in wet rooms, sauna etc. In order to maximize efficiency DomoTecK has added to each heating element a tube for inserting the sensor as well as a 90 right angle bend. 8
Resistance Testing and Warranty Documentation Follow the Resistance Documentation Procedures outlined below and record ALL Ohm Readings on the corresponding Installation Registration Form and the Installation Plan. IMPORTANT! IN ORDER FOR THE WARMTOUCH LIMITED WARRANTY TO BE VALIDATED, THE INSTALLATION REGISTRATION FORM MUST BE COMPLETED IN FULL AND RETURNED TO DOMOTECK INC. It is also essential that a copy of the final installation plan (marked with any changes made in the layout of the system or its electrical connections) be included with the Installation Registration Form. This information will be kept on file with our Technical Dept. so that we are better able to answer questions raised by the distributor who purchased the product(s), the installers, the electricians, and the homeowner. WarmTouch uses electrical resistance to generate heat. Resistance is measured in units known as Ohms. The Digital Ohmmeter or Multimeter used must have a setting of 200 Ohms (for the mats) and 20K (for the floor sensor). If your meter does not have these settings, please check with the manufacturer of the meter to determine THE appropriate setting. The process of checking resistance for all products is as follows: 120 Volt product: Test between the Hot (Yellow or Black) & Neutral (White) 240 Volt product: Test between Line 1(RED) and Line 2 (Black). To test for a short check for continuity between Hot and Ground and between Neutral and Ground. (step 6) 1. Verify that materials shipped match materials ordered BEFORE unwrapping mats. 2. Measure and record the initial resistance of each element. 3. Compare the reading(s) with the Theoretical Ohm Reading(s) chart provided in this manual. If there is more than a +/- 10% difference between the Actual Reading taken and the Theoretical Reading, STOP and CALL our Technical Dept. at 1-800-959-9276 BEFORE CONTINUING with the installation. 4. Compare each ohm reading taken in subsequent steps with the initial ohm readings taken in step 2. 5. Measure and record the resistance of each element (See Step 2) again after customizing the mat(s). 6. Verify that there is no short by checking the resistance between the Hot/Neutral and Ground (Green). There should be no continuity. If there is continuity, STOP and CALL our Tech. Dept. at 1 800-959- 9276 BEFORE CONTINUING with the installation. 7. Measure the resistance of each element (See Step2) again after the heating mat has been secured in place. 8. Measure and record the resistance of each element (See Step 2) again after the mat(s) is embedded in the thin set mortar or self-leveling cement. 9. Repeat Step 4. 10. Attach the white and silver tags in their respective locations, at both the panel box and at the end of the cold leads. This will help identify both the breaker and the mat leads when multiple mats are installed. 9
Element Spacing & Coverage Recommendations Dimension A and B should be equal when possible. Dimension A should never be less than 60% of B. DO NOT ALLOW ANY HEATING ELE- MENT WIRES TO OVERLAP OR ANY COLD LEAD WIRES TO CROSS, TOUCH, OR OVERLAP THE ELEMENT WIRES AT ANY POINT DO NOT HEAT UNDER ITEMS THAT ARE FIXED TO OR FLUSH WITH THE FLOOR (i.e. toilet, cabinetry, etc.) Mat should run directly in front of the base of the vanity to heat the toe kick area properly. Mat can run slightly under the base of the toilet if need be. It should NEVER be placed any closer than 4-6 from the flange. 10
On page 9 see page 10 & following example steps numbered 1-14" 11
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sensor wire must not touch or cross cold leads 9 13
Power source Neutral (white) to T-stat line side neutral (white) - or - Power source line (red) to T-stat line (red) for 240v applications. 14
Troubleshooting Problem Possible cause Solution Cable resistance measurement is different than the nameplate label The control unit is not working at all Use an analog type meter (has a needle to indicate reading) If measurement is showing an open or short-circuit, cable has been damaged. If measurement is just a little low or high, room temperature affected this resistance No power is supplied Defective control unit Obtain a digital type meter with Ohms and re-measure Contact the manufacturer Make the room 75º-85º F, or check with the manufacturer Check circuit breaker, measure voltage at the control Return to dealer for replacement The floor continuously heats Sensor is loose or broken If your control unit has a floor sensor, pull the wires loose and re-insert them. If it still does not work measure resistance across the sensor wires, and compare to the values in the control unit instruction manual The floor is not getting warm Cable has been damaged Measure cable resistance. Check for both "open circuit" and "short circuit" (as detailed earlier in this manual). If damaged, contact the manufacturer. GFCI is tripped Reset the GFCI. If it trips again, check for short circuits in the cable (as detailed earlier in this manual). If damaged contact the manufacturer. If not, replace the GFCI control. Concrete slab floor Surface temperatures rise slowly on a concrete slabs. If after 5 to 8 hours of heating, it is not warmer to touch, check for cable damage (see "cable has been damaged" above). The thermostat is not working correctly Incorrect programming Incorrect voltage supplied Sensor is disconnected or broken Carefully read control unit instructions. Measure voltage at control, make sure it matches the control voltage rating. See "The floor continuously heats" above. 15
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