QuickNet-RK
QuickNet
™
Heating Cable Repair Kit
Installation Instructions
Description
The QuickNet-RK repair kit is for repairing heating cable that is damaged during installation of the QuickNet mat. The kit includes jumper wires to bridge the heating element after the damaged section is removed. The kit contents are sufficient to repair one damaged section up to 5 inches long. If more than 5 inches of cable has been damaged, the mat must be replaced.
Tools Required
• Wire Strippers 16-26 AWG
• Gloves
• Scissors
• Heat gun (1000˚F air temp
with heat deflector required)
• Multimeter (capable of 200K ohms)
Other Required Materials
• QuickNet System Installation Manual (H57704)
• QuickStat Thermostat Installation and Operation Manual (H57725)
Optional Tile Removal Tools
• Grout removal tool • Hammer
Approvals
Kit Contents:
Item Qty Description
A 2 Jumper wires (blue)
B 6 SolderSleeve ® connectors
D 1 Ground wire (non-insulated)
A
B
C
D
WARRANTY & APPROVALS DISCLAIMER
The QuickNet-RK Repair Kit is for making minor repairs to the QuickNet heating cable if it is damaged during or after installation. Because the condition of the damaged mat, site conditions and installer capability can vary,
Tyco Thermal Controls does not warrant the repair or warrant that the repaired floor warming system will function properly. Use of this kit voids the warranty of the repaired portion of the heating cable. Repairs should only be attempted by a qualified electrician or experienced craftsmen familiar with good electrical practice and techniques for tile installation and removal.
Contact Tyco Thermal Controls for assistance.
WARNING:
WARNING: Shock and Fire Hazard.
If the QuickNet mat is damaged or not installed properly, fire or shock could occur resulting in serious personal injuries or damage to property. You must carefully follow the warnings and instructions contained in these instructions and the QuickNet
Installation Manual (H57704). Contact Tyco Thermal
Controls for assistance.
• The QuickStat thermostat must be used. It has a ground-fault circuit interrupter (GFCI) to prevent electric shock.
• The QuickNet-RK repair kit must be installed by qualified personnel familiar with generally accepted construction techniques and safe electrical practices. The installation must comply with all national and local electrical codes. If you are unfamiliar with these requirements, contact a licensed electrician.
• Electric wiring and the heating mat are installed in the floor. Be sure that the floor is not penetrated by nails, screws, or similar devices that can cause damage on first installation or during subsequent floor repairs in the future.
• Do not use this Repair Kit to splice different QuickNet mats together. It is designed only to repair a damaged section of heating cable in a single mat.
• The QuickNet heating cable cannot be cut to length, crossed over itself, or installed closer than the spacing in the mat.
INSTALLATION GUIDELINES:
• QuickNet mats can only be installed beneath ceramic tile or natural stone surfaces. Do not install beneath wooden, carpeted, linoleum, or other type floors.
• Do not step directly on or damage the heating cable during installation.
• Do not install the QuickNet mat across expansion joints.
• Follow the manufacturer’s instructions for installing tiles, scratch coat, thin-set mortar, or quick drying mortar beds.
• Do not allow heating cable, cold lead, or floor temperature sensor to cross over themselves or each other.
2
QuickNet-RK Installation Instructions
1
• Turn off the power to the QuickNet floor warming system at the circuit breaker before starting any repair work.
3
• If the damaged section has not been installed in mortar, proceed to Step 7.
• Remove the tile above the damaged section by removing the grout with a removal tool, being careful not to further damage the heating cable. Do not use a knife or chisel.
2
• Disconnect the QuickNet cold leads, power wires and floor sensor leads from the the QuickStat Thermostat. This provides additional safety and allows for the testing required in later steps.
Back of thermostat
Power
QuickStat
GFCI Clas
LINE s A
L1 (L)
240/(120)V
L2 (N)
AC
16A)
40W VOL 1920
LOAD fore nnec ly be Dis pow
CAUTI
16A
Max.
Ground
Cold leads
Floor sensor leads
QuickStat ®
GFCI Class A
LINE
L1 (L)
240/(120)VAC
L2 (N)
LOAD
16A
Max.
Line
(black)
Neutral
(white)
Cold lead
Cold lead
Floor sensor leads
4
• Once the grout is removed, carefully break away the tile using a hammer.
Heating cable
Damage location
5
• Remove any broken tile and vacuum other debris from the exposed surface to locate the damaged heating cable section.
6
• To expose the damaged section, break mortar away from the heating cable with the hammer, making sure not to damage the cable.
7
• Remove sufficient mortar to expose 4-5 inches of heating cable on either side of the damage. Using scissors cut the mesh from the cable to provide room to install the splice.
3
QuickNet-RK Installation Instructions
8
• Remove at least 3 inches, and up to 5 inches of heating cable including the damaged section leaving two protruding ends of heating cable. If more than 5" of cable has been damaged, the mat must be replaced.
3-5"
9
• Remove the damaged section.
Damaged section
10
• Using the 16 AWG opening on the wire strippers carefully score the outer jacket, 2 inches from the end of both exposed heating cable ends.
2"
2"
11
• Flex the cable to break the insulation at the score.
12
• Using the high setting on the heat gun, heat the jacket to loosen the insulation.
Heating cable
Score
4
QuickNet-RK Installation Instructions
13
• While the cable is still hot, use strippers to remove the outer jacket and foil layer to expose the heating elements.
• Cut off the colored thread.
Outer jacket Foil layer
Colored thread (1)
Heating elements (2)
Grounding wire (2)
14
• Twist two ground wires together.
15
• Heat only 1/2" of the insulated ends of the heating elements to soften.
16
• While the wires are still hot, use the wire strippers to remove
1/2" of the outer insulation to expose the heating elements.
1/2"
17
• Repeat steps 9 - 15 for other exposed heating cable end.
18
• Test both ends of the heating cable using this insulation resistance test to verify there is not further damage to the heating cable.
1. Connect the ground wire to the black lead and both power wires to the red lead of the multimeter.
2. Make sure the meter reads ‘Open’ or “OL’. If you get a different reading, contact Tyco Thermal Controls at 800-545-6258.
3. Record these readings on the Commissioning Record (page 8).
19
• Cut jumper wires to length allowing for 1/2" overlap on each end as shown.
1/2"
1/2"
5
QuickNet-RK Installation Instructions
20
• Strip 1/2" of insulation off both ends of each jumper wire.
1/2"
21
• Slide SolderSleeve connector onto one heating wire.
• Insert jumper wire into SolderSleeve connector.
Jumper wire
SolderSleeve
Heating wire
22
• Heat SolderSleeve connectors until solder and adhesive have melted. (The colored solder ring will turn clear when melted.)
• Allow to cool, then repeat for second jumper wire.
23
• Slide two heat-shrinkable tubes onto each jumper wire.
24
• Slide SolderSleeve connector onto one heating wire.
• Insert jumper wire into SolderSleeve connector.
6
QuickNet-RK Installation Instructions
25
• Heat SolderSleeve connectors until solder and adhesive have melted.
• Allow to cool, then repeat for second jumper wire.
26
• Center the 4 black heat-shrinkable tubes over the installed
SolderSleeve connectors.
• Using the heat gun, shrink in place.
27
• Cut ground jumper to length, allowing 1/2" overlap on each end of twisted grounding wire.
28
• Slide SolderSleeve connectors onto ground wires and jumper.
1/2"
29
• Heat SolderSleeve connectors until solder has melted.
1/2"
30
• Before and after re-installing the mortar and tile run the three standard QuickNet commissioning tests from the cold lead wire at the QuickStat Thermostat and record the results in the commissioning log.
• Continue the QuickNet System installation following the
QuickNet and QuickStat Installation manuals.
7
QuickNet-RK Installation Instructions
Once the QuickNet splice is completed, conduct the following three commissioning tests on this page and record the values on the QuickNet-RK
Commissioning Record (on page 8). Retain these readings with the original QuickNet Commissioning Record.
Testing Procedure
1 Insulation Resistance Test
This test ensures that the insulating jackets of the mat are not damaged. A low value indicates the mat has been damaged and must be replaced.
2 Heating Cable Resistance Test
This test measures the resistance of the mat and is used to determine circuit integrity.
Cold lead
White
Black
Ground
R = Open
or OL
1. Connect the ground wire to the black lead and both power wires to the red lead of the multimeter.
2. Set your multimeter to the 200 K ohm range. Make sure the meter reads ‘Open’ or “OL’. If you get a different reading, contact Tyco Thermal Controls at 800-545-6258.
3. Record these readings on the Commissioning Record (page 8).
R = ?Ω
See Table 1
1. Set your multimeter to the 200 ohm range.
2. Connect the multimeter leads to the black and white cold lead wires.
3. Compare this resistance reading to the resistance specified in the QuickNet Resistance Table below. The value should be within ±10%. If you get a different reading, contact Tyco Thermal
Controls at 800-545-6258.
4. Record these readings on the Commissioning Record (page 8).
3 Sensor Resistance Test
This test measures the resistance of the floor sensor and is used to verify the sensor integrity.
Red
Green
R = 9 – 25 KΩ
1. Set your multimeter to the 200 K ohm range.
2. Connect the multimeter leads to the red and green lead wires.
3. Make sure the meter reads between 9–25 KΩ.
If you get a different reading, contact Tyco Thermal Controls at 800-545-6258.
4. Record these readings on the Commissioning Record (page 8).
QuickNet Mat Resistance Table
120 V QuickNet with thermostat
Catalog Number
QUICKNET-010-1
QUICKNET-020-1
QUICKNET-030-1
QUICKNET-040-1
QUICKNET-050-1
QUICKNET-060-1
QUICKNET-070-1
QUICKNET-080-1
QUICKNET-090-1
QUICKNET-100-1
Size ft² (m²)
10 (0.9)
20 (1.9)
30 (2.8)
40 (3.7)
50 (4.6)
60 (5.6)
70 (6.5)
80 (7.4)
90 (8.4)
100 (9.3)
20
17
15
13
12
Resistance Ohms
120
60
40
30
24
240 V QuickNet Mats with thermostat (and without thermostat)
Catalog Number
QUICKNET-050-2 (-050X-2)
QUICKNET-060-2 (-060X-2)
QUICKNET-080-2 (-080X-2)
QUICKNET-100-2 (-100X-2)
Size ft² (m²)
50 (4.6)
60 (5.6)
80 (7.4)
100 (9.3)
Resistance Ohms
96
80
60
48
8
QuickNet-RK Installation Instructions
QuickNet-RK Cable Repair Commissioning Record (retain this record)
Installer
Date of commissioning:
Name of installer:
Street:
City:
Phone (offi ce):
Fax:
Website:
Company:
Postal code:
Phone (mobile):
Email:
Project data
Street:
City:
Sub fl oor type:
Wood
Kitchen
Entryway
Concrete
Other:
Postal code:
Floor
Ceramic tile Natural stone
240 V
Recorded value
Insulation resistance
Batch date (from box or cord label):
Before embedding in mortar*:
After embedding in mortar*:
After fl oor covering*:
(KΩ)
(KΩ)
(KΩ)
Heating cable resistance Before embedding in mortar*:
After embedding in mortar*:
After fl oor covering*:
(Ω)
(Ω)
(Ω)
Before embedding in mortar*:
After embedding in mortar*:
(KΩ)
(KΩ)
After fl oor covering*: (KΩ)
* Refer to QuickNet Installation Manual (H57704) for further installation and testing details. Available online at www.tycothermal.com.
Installer: Please leave this record with homeowner.
Worldwide Headquarters
Tyco Thermal Controls
300 Constitution Drive
Menlo Park, CA 94025-1164
USA
Tel (800) 545-6258
Fax (800) 596-5004 [email protected]
www.tycothermal.com
Tyco, QuickNet, QuickStat, Raychem and SolderSleeve are trademarks or registered trademarks of Tyco Thermal Controls LLC or its affiliates.
Canada
Tyco Thermal Controls
250 West Street
Trenton, Ontario
Canada KBV 5S2
Tel (800) 545-6258
Fax (800) 596-5004
Important: All information, including illustrations, is believed to be reliable.
Users, however, should independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal Controls' only obligations are those in the Tyco
Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition,
Tyco Thermal Controls reserves the right to make changes—without notification to Buyer—to processing or materials that do not affect compliance with any applicable specification.
