Installation Manual for your TempZone™ Electric Radiant Floor

Installation Manual for your TempZone™ Electric Radiant Floor
Installation Manual for your
TempZone™ Electric Radiant
Floor Heating System (Twin Conductor)
Free Design Service • 24/7 Installation Support • No Nonsense™ Warranty • (800) 875-5285 • www.WarmlyYours.com
1
Understanding The System
How The System Works
You can feel the heat of a campfire even though you are
not directly above it. Radiant energy transfer is caused by
a warm surface (the campfire) giving up its heat to a cooler
surface (your body). This radiant energy travels through
space without heating the space itself. It only turns into
heat when it contacts a cooler surface. By transferring this
heat to all of the objects in the room, the heat slowly moves
to warm the air which starts to rise.
Proper Heat Dissipation
All radiant heating systems rely on a “Heat Bank”. The heat
moves from the source (Heating Element) into the Heat
Bank (thin-set) and spreads out and warms the floor without
creating an excessively hot spot. In the WarmlyYours
Floor Heating System the thin-set and/or self-levelling
cement acts as the Heat Bank. It is important to follow the
installation guidelines to create a proper Heat Bank.
Insulation – Proper Heat
Retention
When WarmlyYours floor heating systems are installed on
a concrete slab, we strongly recommend adding a layer
of insulation to the slab prior to installing the radiant floor
heating system.
While WarmlyYours systems provide up to 25% more
heating power per square foot than the nearest competitor,
the slab will always act as a “heat sink.” Some of the
heat that would otherwise be transferred to the flooring
surface will remain in the slab, causing the floor’s surface
temperature to be considerably lower. This is true with any
floor heating system.
When installed on top of a concrete slab without insulation,
it is generally accepted that a radiant floor heating system
will take the chill away from the floor and provide a small
amount of warmth.
Adding insulation on top of the slab and beneath any floor
heating system will allow a greater percentage of the heat
generated to transfer to the flooring surface.
1
This leads to greater efficiency and therefore faster warm
up times, higher expected surface temperatures and lower
energy usage. The floor will have the capacity to warm
to a comfortable temperature, and in some cases can be
employed as the primary heat source for that room.
Securing The Roll(s)
Once the roll(s) is fitted into the space, it needs to be
secured to the subfloor to prevent movement during the
installation of the floor covering. The options for securing
the roll(s) are discussed in detail on Page 5. Regardless
of the method you choose, it is vital that the integrity of
the Heating Element be maintained. Staples should never
cross, pierce or nick the Heating Element. Minimum 2 in.
spacing between adjacent heating devices.
Protecting The Heating Element
It is vital that proper care be taken to insure that the
Heating Element is not damaged during the installation of
the system or by the floor covering. A thorough preparation
and detailed inspection of the subfloor will assure that any
and all objects that may damage the Heating Element are
removed prior to installation. Heavy gauge cardboard or
carpet scraps should be used to protect the system from
traffic during the flooring installation.
Never Cut The Heating Element
The key to the system is the uninterrupted flow of
electricity through the Heating Element.
Control Device Options
Option 1: Programmable
Thermostat
The SmartStat has an in-floor
sensor and a digital display
that indicates the exact floor
temperature. It also features a
manual set-back to a “high” and
a “low” temperature level, and a
built-in GFCI. The programmable
function allows you 4 setting
changes for each day of the week.
Its maximum capacity is 1800
watts at 120 VAC or 3600 watts
at 240 VAC . Any floor requiring
more power will need to be zoned
with more than one SmartStat™
and a Relay Contactor or with a
Master Thermostat and Power
Modules.
Option 2: EasyStat
Non-Programmable Thermostat
The EasyStat™ has an in floor
sensor just like the SmartStat™,
but requires no programming.
Just enter the floor temperature
using either Fahrenheit or Celcius.
It is equipped with a GFCI and
is available in 15 amps at both
120 volt and 240 voltages. A floor
requiring more power will need
to be zoned with more than one
SmartStat and a Relay Contactor
or with a Master Thermostat and
Power Modules. We recommend
an inside wall, away from
sunshine.
Items Needed For The System Installation
System Components From WarmlyYours
Ground Fault Circuit Interrupter
1. The Customized Installation Plan (or layout).
GFCI or ‘GFCI-breaker’ indicating its capacity if not incorporated into the control device
you are using. This is a built-in feature of the SmartStat Programmable Thermostat,
EasyStat or Comfort Regulator.
2. Heating Roll(s) (15-watt/ sq. ft.) If multiple rolls are connected to the same control
device, they must be of the same voltage type and wired in parallel.
3. Control Device (one of the following):
• SmartStat™ Programmable Thermostat
• EasyStat™ Non-Programmable Thermostat
• Comfort Regulator
4. You may also have a relay contactor or power module, if your system is being
installed in a large area.
IMPORTANT - Cross check the items you received against the packing
list and the materials list on the installation plan to ensure that the roll
length(s) and thermostat type(s) are an exact match.­­
Digital Ohm Meter (multi-meter)
Test the Heating Roll(s) before, during, and after the installation. A digital meter is strongly
recommended because of the precise measurements needed.
Electrical Housing Boxes/Switch Plates
All control devices except a Relay Contactor fit into a deep single gang box. If a double
gang box is used it will need to be fitted with a single gang mud ring. We strongly
recommend a double gang box with a single gang mud ring as it provides more room
to place all the wires. Heating elements of cables shall be separated at least 200mm (8
in.) from the edge of outlet boxes and junction boxes that are to be used for mounting
surface luminaires. A clearance of not less than 50 mm (2 in.) shall be provided from
recessed luminaires and their trims, ventilating openings, and other such openings in
room surfaces. No heating cable shall be covered by any surface-mounted equipment.
Electrical Conduit
Local electrical codes often require the power leads be inside a metal or plastic conduit
when running through the wall from the Heating Roll to the control device. When using an
in-floor sensor, if local code requires the low voltage sensor wire be housed in conduit, it
must use a separate conduit from the power leads(high voltage).
A Permanent Marker And Tape Measure
To measure and mark Installation Plan points onto the prepared subfloor as well as where
to alter the Fiberglass Mesh of the Heating Roll(s).
Utility Scissors
Double Check Your Dimensions
Check and verify that your plan has the correct room dimensions. Your order consists of
the exact amount of material required to complete your project. If the measurements of
your space have changed, this will affect how much product is required and how it will be
installed. Once the Heating Roll is cut into panels, it cannot be returned. If you have any
discrepancies or questions, call WarmlyYours at (800) 875-5285.
Scissors are the best tool to trim and alter the Fiberglass Mesh of the Heating Roll and to
separate any lengths of Heating Element from the Mesh. Never cut the Heating Element.
Hot Glue Gun, Double-Sided Tape and/or Stapler
Use these tools to affix the Fiberglass Mesh portion of the Heating Roll to the prepared
subfloor before covering with thin-set cement. Beware that misuse of a stapler can cause
damage to the Heating Element. NEVER staple across or on top of the wires. Hi-temp
duct tape, like 3M 6969 is suggested.
Circuit Check (Not a substitute for an OHM meter)
Off-Cuts Of Cardboard Or Carpet Scraps
This device is offered in every order from WarmlyYours and is a continuity checker that
you connect to the cold lead wires before installation of the flooring material.
This protects the Heating Element during the installation.
2
Understanding The Customized Installation Plan
The Customized Installation Plan
This is your key to a successful installation. Your plan has been custom designed
for your individual project based on the dimensions you gave us. It will indicate the
placement of each Heating Roll, the electrical service requirements, and the location
of the control device(s). It should be reviewed to verify that the dimensions of your
room are accurate as well as the location of the permanent fixtures in your space. If
you have made any alterations to your floor plan, contact WarmlyYours to have
your Installation Plan updated.
A. Materials List:
Indicates the items included in your order.
B. Legend:
Description of the items on the Installation Plan.
C. Starting Point:
Indicates where the Heating Roll(s) starts.
D. Ending Point:
Indicates the end of the Heating Roll(s).
E. Turn:
Indicates where the “Mesh” needs to be cut to make a turn allowing the roll to continue
in a new direction. See Page 5 for full details on how to execute turns.
F. Free Form Space:
Indicates a length of Fiberglass Mesh that needs to be removed and separated from the
Heating Element. For every 3” of Mesh removed, 1’ 6” of Heating Element will be freed.
This “free” wire should be manually positioned on the floor and secured with tape or glue.
Staples are never recommended on the Heating Element.
G. Control Device:
Indicates where the control device is to be located on the wall.
H. Notes:
Indicates any additional information you may need including the total watts and amps
drawn by the Floor Heating System.
I. Permanent Fixtures:
Indicates the location of permanent fixtures. Please note that these fixtures must not be
placed on top of the heated area.
IMPORTANT - Cross check the items you received against the packing
list and the materials list on the installation plan to ensure that the roll
length(s) and thermostat type(s) are an exact match.
3
Warmlyyours Floor Heating System.
The Heating Roll
A. Heating Element
B. Fiberglass Mesh
C. Tape
D. Cold Lead Wire
E. Factory Splice
F. Floor Sensor (optional)
Secondary Teflon
Insulation
Relay Contactor or Power Modules
(not required for all systems)
Systems installed in large spaces will most likely require a Relay
Contactor or Power Module(s) in addition to the control device
to operate properly. The Relay or the Power Modules may be
located in the same vicinity as the control device. If your system
will be using this option, all cold leads will be connected to the
relay contactor or power module and not directly to the control
device.
E
Metal Braiding
Connected to Ground
F
Multi Strand
Conductor Wire
Primary Teflon
Insulation
The Heating Element
The Heating Element consists of two copper alloy resistance wires covered by Teflon™ insulation. A braided metal
surrounds the primary Teflon™ insulation and serves as ground sheath. The Heating Element (A) attached with tape
(C) in a serpentine pattern to a flexible Fiberglass Mesh (B). The Fiberglass Mesh is designed to keep the Heating
Element evenly spaced throughout the roll. The cold lead return wire is factory installed at one end of the Heating
Roll and must run back to the power supply along the perimeter of the heated space. The power lead (D) is 15-feet in
length. The lead is spliced to the Heating Element (E) at the factory. If necessary, this lead wire may be shortened or
even extended. Please note the thickness of the factory splice and cold lead and plan accordingly.
Floor Sensor (not required for all systems)
Systems using a SmartStat Programmable Thermostat or EasyStat require a Floor Sensor (G). This Sensor is
embedded in the floor and monitors the floor temperature. The Floor Sensor should be centered in between 2 resistance
wires leaving approximately 1” on either side and extend about 6” into the heated area. Avoid placing the sensor in an
area affected by a draft, a radiator or the sun. Must be installed if using a thermostat. Some people choose to install a
second (Backup) sensor. For an additional cost you may purchase a second sensor.
Heating Roll(s): Types and Sizes
Roll(s) are rated at 15-watts per square foot and vary in length.
Each roll is designed to draw a specific amount of electricity
and therefore produce the proper amount of heat based on its
length. For this reason, the length of the roll(s) can never be
shortened to make a proper fit. Your Installation Plan has been
designed to specifically accommodate your space. The same is
true for rooms that have multiple rolls. Multiple rolls are never
wired to each other. Each roll is wired in parallel to the control
device or relay contactor.
Working with the Heating Roll(s)
The roll(s) that make up your system have been selected to
fit into your floor plan. The Installation Plan shows precisely
where each roll starts and ends. The “Lead Wire” on each roll
is designed to travel back to the control device location. These
wires do not heat. All connections are made at this point. While
it may be required to cut and alter the “Fiberglass Mesh”, the
“Heating Element” must stay intact. Page 5 shows in detail
how to make the necessary turns to install your Floor Heating
System.
Separating the Heating Element
from the Mesh
During the installation, you may need to separate the Heating
Element from the Fiberglass Mesh. This can be done provided
the Heating Element is not cut and the shielding is not nicked
or punctured. It will be necessary to do this when releasing the
Heating Element to make step turns and position it in a “Free
Form” space.
4
­One Good Turn Deserves Another
The complimentary Installation Plan provided by the
WarmlyYours team is very important. It shows the
recommended placement of your Heating Roll(s) for
safety and optimal efficiency. The plan will also serve
as the reference for any future inspections or floor work
that needs to be performed.
The Heating Element of the WarmlyYours product is
sewn in a serpentine pattern onto lengths of Fiberglass
Mesh forming a roll. It is quick and simple to cover large
areas.
Your plan shows you where any modification is
necessary. These are all easily done by cutting through
the Fiberglass Mesh material (NOT the Heating
Element), see Photo A , so that the roll is in two or more,
moveable -but connected- pieces which are called
“Panels”, see Photo B. These panels can be angled,
turned or completely flipped over in order to cover the
space.
To cover very small or odd shaped areas, the Heating
Element is used in “Free Form”. A section of the
Fiberglass Mesh is removed in order to release an
appropriate length of Heating Element to fill the space.
This “free” wire is placed in areas not reached by the
main Heating Elements of the panels. It is also used to
make “step turns” possible. Always maintain 3” spacing
in all free form and step turns.
To release the required amount of Heating Element for
a free form area, first make the two straight cuts and
then carefully remove it.
Cut & Turn
By cutting only the Mesh (see Photo A), you can move
the remaining section of the Heating Roll in a new
direction. By doing this, you are creating what are now
referred to as “panels.” (see Photo B). This is the first
step in any turn or alteration of the Heating Roll(s). A
turn is indicated on the Installation Plan by an arc with
an arrowhead. By examining the relationship between
two panels, you will determine the type of turn needed.
Minimum installation temperature for the wire is 5ºF
(-15ºC). See Adhesive instructions for recommended
minimum installation temperature.
Free Form
Free form spaces are filled with loose lengths of Heating
Element. A wavy line with an arrow will appear on the
Installation Plan to indicate the area that needs to be
filled. This symbol is accompanied by a unit of measure
in a circle that will indicate the amount of Fiberglass
Mesh to be removed. (See Page 6, on Installation
Plan.) Once the tape is trimmed, the Heating Element
separated and the Fiberglass Mesh removed, position
the Heating Element by hand and secure it to the floor
with Hot Glue or Tape. Try to maintain the 3 inch spacing
similar to the spacing on the Heating Roll(s).
Photo A
Installation Recommendations
The space heating cable shall not extend beyond the
room or area in which it originates.
The space heating cable is not installed in closets,
over walls or partitions that extend to the ceiling, or
over cabinets whose clearance from the ceiling is less
than the minimum horizontal dimension of the nearest
cabinet edge that is open to the room or area.
Isolated single runs of cable may pass over partitions
where they are embedded.
The cable is not to be installed in walls.
The minimum distance between adjacent runs shall be 2 in.
Inspect and remove damaged or defective cables
before they are covered or concealed.
5
Mark the appropriate circuit breaker reference label
indicating which branch circuit supplies the circuits to
those electric space heating cables.
Photo B
­One Good Turn Deserves Another
Step Turn
Step Turn with Flip Over
Start
Cut and remove the amount of Fiberglass
Mesh indicated in the circle and then
make a U Turn. The released Heating
Element is then placed in a free form
manner in the stepped gap. (See Free
Form this section) This is the most popular
way to do a step turn because it keeps the
Heating Element under the Fiberglass
Mesh offering some protection during floor
covering installation.
Finish
Start
Working
around Obstacles
Special circumstances will require the
Heating Element to circumvent an
obstacle. The released Heating Element
is not needed to fill an area but to simply
continue the circuit.
Experience is the Key
As you begin to work with the Heating
Panels, you will become more comfortable
with the product. The ultimate goal is to
keep even spacing of the Heating Element
and the integrity of the electrical circuit.
Cut and remove the amount of Fiberglass
Mesh indicated in the circle.
Cut and remove the amount of Fiberglass
Mesh indicated in the circle and make
a 180° flip turn. The released Heating
Element is placed in a free form manner in
the stepped gap. (See Free Form) Some
installations will require a Heating Panel
to be placed with the wires facing up.
We recommend that at the next turn the
panel should be flipped over so that the
Fiberglass Mesh sits on top of the Heating
Element.
Finish
6
Testing
DO NOT SUPPLY THE SYSTEM WITH
ELECTRIC CURRENT
Go by the Numbers
All testing is done with a digital Ohmmeter. Supplying the system with a 120 volt or 240
volt electric current before the installation is complete is not needed to test the system.
Taking the Ohm Readings
The electrical resistance of the Heating Roll(s) must be checked before you start, and
monitored throughout the installation process to ensure there has been no damage
causing shorts or breaks. We recommend at least three readings be taken:
1. Before starting installation.
The Ohm resistance should be measured from the inner core of the yellow (120V), or
red (240V) lead wire at one end, to the inner core of the Black lead wire at the other end.
Make sure that the probe of the Ohmmeter does not touch the tinned sheath wire at either
end. Even your body’s electrical resistance can affect the reading if you touch the meter
poles. Do not hold the wires onto the probes with your fingers. A digital meter is easier to
use and strongly recommended. It is wise to verify that the batteries of the Ohmmeter are
good. Set your Ohmmeter to measure resistance in the range of 0 to 200 Ohms.
On some smaller rolls, it may be necessary to set the ohm meter to the next higher range
of measurment to get an accurate ohm reading.
Three (3) Ohm Readings should be taken for each roll of WarmlyYours TempZone at each
stage of the installation and recorded in the table below.
2. After securing the Heating Roll(s) in place on the subfloor.
3. After installing the flooring surface above the Heating Roll(s).
Record the Ohm Readings
The Value on the UL label should be within +/- 15% variance of the original measurement
indicated on the label. The electrician should carefully mark the initial Ohm reading taken
onto the warranty card. Should the initial Ohm reading be outside the 15% +/- variance,
refer to the electrical trouble shooting section on Page 14, or call Technical Support at
(800) 875-5285.
1) Core to Core - This is the reading between the two inner conductors on the lead wires.
2) C
ore to Sheath Yellow / Red Lead - This is the reading between the inner core and
the outer ground sheath on the lead wire. This reading should be infinity.
3) C
ore to Sheath Black Lead - This is the reading between the inner core and the outer
ground sheath on the lead wire at the finish point of the roll. This reading should be
infinity.
Core to Core
Catalog Number
Black
Yellow Yellow
Yellow
or Red or Red
or Red
Wattage
Sheath to Sheath
Black
Black
Ground Ground
Ground
Yellow Yellow
Yellow
or Red or Red
or Red
Core to Sheath
Ground Ground
Ground
Black
Black
Black
Serial Number
Voltage
Usage
Refer to
Instructions
7
A ground fault
protection device
must be used with
this heating device.
After the installation, if necessary, the position of a break can be found with a time domain
reflectometer. Repair kits and guidance are available from the WarmlyYours support line.
Details of how to repair a damaged Heating Element are also available on our web site at
http://www.warmlyyours.com/en-US/support.
Example of Wiring a Control to Twin Conductor
Twin Conductor
Secondary Teflon
Insulation
Turn off Breaker
Metal Braiding
Connected to Ground
1. Using a wirenut, attach line (240V) or neutral (120V)
from breaker box to top, red wire on the thermostat
labeled: “L2(N)”.
Multi Strand
Conductor Wire
2. Using a wirenut, attach line (240V & 120V) from
breaker to bottom, black wire labeled: “L1(L)”.
FROM POWER SOURCE
120V & 240V
C
ENREGISTRE
US
HOT
3. Using a wirenut, attach red wire (yellow for 120V)
from heating, roll to the lower, red wire labeled: “load
”.
4. U
sing a wirenut, attach black wire to upper black
wire labeled: “Load ”.
5. Using a wirenut, attach the ground wire of heating
roll to the ground wire in the wallbox.
For installation in an
adhesive bed, self leveling or
mortar cement
RADIANT HEATING PANEL UNIT
UNITE DE PLANCHER
CHAUFFANT ELECTRIQUE
8PA5
Installation avec ciment, mortier
colle ou colle a carrelage
Resistance / Ohm
Black
Primary Teflon
Insulation
TempZone Electric Floor
Heating Panel
Plancher Chauffant Electrique
HOT (240V) or LISTED
HOUSE GROUND
NEUTRAL (120V)
Red
Core to Core
Tension a Tension
: 105.3 Ohm
Grd Sheath to Grd Sheath
Prise de terre a Pdt
: 1.02 Ohm
Output Unit W
Puissance de l’unite
: 135
Spez. output W/sqf
Puissance au pied carre : 15 W
Voltage
: 120V/60 Hz
Length / ft
Longueur en pieds
Width / ft
Largeur en pieds
:9
: 1.0
SKU
S/NO
C/O INDIA Made by Thermopads Pvt. Ltd. for WarmlyYours.com Inc.
Red (240) or
Yellow (120) Wires
THERMOSTAT
1
6. Turn on breaker.
L2 (N)
Load
2
Copper
Ground
L1 (L)
5
Red
3
4
Black Lead
Black
Double Gang Box with a
Single Gang Mudring
8
Installer’s Guide
STEP 1
STEP 2
STEP 3
Electrical Planning
Prepare the Subfloor
Mark the Floor
The power supply to the Floor Heating
System and the control device will be located
at the same point in the room and indicated
on your plan. If this location has changed, call
WarmlyYours to determine if this will require
a new Installation Plan. The lead wire is 15’
long. You can relocate the control device as
long as your leads reach the new location.
Inspect the subfloor surface carefully.
Remove all debris and grind any sharp edges
of cracks. It is important to remove any sharp
edges or pointed objects that might damage
the Heating Element.
Using a suitable pen, and referring to the
Installation Plan provided, mark off areas on
the floor where permanent/heavy fixtures will
rest. (Cabinets, toilet base, etc.)
The thermostat requires a deep single or a
double gang box with a single gang mud ring
and should be positioned in a convenient
place for easy access. From the gang box,
two sets of wires will go to the floor:
We strongly recommend adding a layer
of insulation to the concrete slab prior to
installing the floor heating system. Secure
the insulation to the subfloor before installing
the floor heating system. The insulation will
increase the efficiency of the system and will
ease placement of the cold lead.
Set 1) T
he 120-volt or 240-volt cold lead
wires that power the system
Expansion
joints
require
special
consideration. Heating panels cannot cross
these joints and your Installation Plan should
accurately indicate all joints. If your Installation
Plan does not match your subfloor, contact
WarmlyYours to have a new plan designed.
Set 2) T
he low voltage sensor wire if a
SmartStat or EasyStat thermostat is
being installed.
Some local electrical codes require the low
voltage and/or 120-volt wires above the floor
to be installed in conduit. The low voltage
sensor wire must not be placed in the
same conduit as the 120-volt or 240- volt
power supply. The portion of the cold lead
that is installed in the floor will be directly
covered with thin-set cement or flooring
adhesive.
All lead wires will travel back to the control
location (either directly or through a Relay
Contactor) AND MUST NOT CROSS OR
COME IN CONTACT WITH THE HEATING
ELEMENT.
Check the Ohms reading of the sensor wire
before and after installation to make sure it has
not radically changed. Most sensor wires have
Ohms readings of 8,000 to 20,000 and your
OHM meter must have a 20kohm setting for this
measurement.
9
Cement Subfloors Insulate for Heat Retention
Cementboard Subfloors
Remove all debris, staples and nails. Repair
any loose boards and sand the edges of any
boards that are at different elevations. First
apply a 1/8” to 1/4” layer of thin-set cement
and let it dry.
Mudbed Subfloors
The Heating Roll(s) are always installed on
top of the Mudbed in the thin-set used to
adhere the tiles.
It is advised to prepare the subfloor as you
would for any conventional installation along
the Tile Council of America Guidelines.
Once installed over the sub-floorings
described, at least 1/4 in. of thin-set or mortar
type cement/adhesive material is to be
installed over the heating panel. The flooring
materials that may be installed on top of the
cement/adhesive material cannot have an
insulation value greater than R-1.
STEP 4 cont.
designed on the Installation Plan. Remember
that if you extend 4 panels by 3”, at the end
you will be missing a 1’ length of Heating Roll.
Plan any deviation from the Installation Plan
accordingly.
Mark the position of the sensor (if one is to
be used) as well as the planned route of the
cold lead wires and sensor wire (if used).
Please note diameter of cold lead and plan
accordingly.
IMPORTANT
Indicate where the Heating Roll(s) will need
to be cut and the Fiberglass Mesh will be
removed to customize the roll(s) with flips,
turns and where freeform spaces will be
located as indicated on your Installation Plan.
Careless use of tools and excessive
traffic during the next few steps is
the leading cause of damage to the
Heating Element. Never drop or bang
a tool on the Heating Element.
Refer to Page 6 to understand how to
customize and alter the Heating Panels with
flips, turns and freeform spaces.
Refer to Page 9 to develop an understanding
of where the Heating Panels need to be
STEP 4
placed in relation to permanent fixtures and
trafficked areas.
Mark the Roll
On the Heating Roll(s), mark the location for
the planned cut and turns and the length of
the free form cuts. Do this from the beginning
to the end of the roll; this is the last time
you can make sure that the total of all panel
lengths on your Installation Plan is the same
as the length of the roll you received.
If there are any changes or discrepancies
with the Installation Plan, you will be able
to choose different locations for the cut-&turns, but the reference marks on the roll will
help you to always know if you are effecting
turns a few inches ahead-or-behind what was
STEP 5
Minimize walking on the Heating
Elements and remember that when
rising from a kneeling position, toecaps
may exert too much uneven pressure
on the elements.
We recommend the use of thick scraps
of cardboard or carpeting squares to
reduce the risk of damage.
Make sure that everyone involved
in the installation or performing
other work in the space during the
installation process is aware of the
extra care needed to protect the
Heating Element.
Ceramic Tile & Natural Stone Floors - Step-by-Step Installation Guide
Materials
and Tools Required:
• WarmlyYours TempZone Heating Rolls
• Thermostat with Sensor Probe Wire (if applicable)
Preparation:
1. Cross check the items you received against the packing list and the materials list
on the installation plan to ensure that the roll length and thermostat type are an
exact match.
• Circuit Check (sold separately)
2. Perform 1st ohm test - Measure the resistance of each mat with an Ohm meter
(reading core wire to core wire) and record the readings on the UL label and on
the installation plan. The Ohms readings should be within a +/- 15% variance of
the Ohm value specified on the UL tag. Measure the continuity between each core
wire and ground wire – The reading should be O/L or infinity.
• Scissors
3. Prepare the subfloor to be clean and free of debris.
• Staple Gun or Hot Glue Gun (concrete applications)
4. Do a dry fit of the rolls on the subfloor according to the custom design/installation
plan. Measure and mark the mats and subfloor if necessary.
• Custom Design Layout (provided free with quote)
• Digital Ohm Meter (required for completion of warranty registration card)
• Duct Tape or Box Tape (we recommend 3M 6969 Hi-Temp Duct Tape)
• Latex-Portland Cement (acrylic or latex modified thin-set mortar)
• Plastic Notched Trowel
• Self-leveling Cement
• ¼” Cork or 3/16” CeraZorb® concrete insulating underlayment (WarmlyYours offers
both of these products), or similar, is recommended when installing over concrete.
This is recommended to increase efficiency, but is not mandatory.
See Thermal Insulating & Sound Control Underlayment installation
instructions. We do not recommend using self-leveling cement directly over cork
insulating underlayment. However, self-leveling cement can be used directly over
CeraZorb® insulating underlayment.
5. Make any adjustment in the layout PRIOR to cutting the roll.
6. When using Self-Leveling Underlayment (SLU), we suggest priming the floor
before laying out the rolls. Doing so will ensure that the primer covers the
subfloor completely. Whenever using SLU, ALWAYS follow the installation
recommendations set forth by the SLU’s manaufacturer. It is very important to
adhere the heating roll securely to the subfloor, otherwise the heating wire may
float to the top of the SLU.
Please call WarmlyYours at (800) 875-5285 if the roll does not provide the specified
coverage or for 24/7 installation and technical support.
10
Ceramic Tile & Natural Stone Floors - Cont.
STEP 1
STEP 2
STEP 3
STEP 4
Dry-Fit /
Cutting & Turning
Install Warmlyyours
Heating Rolls
Tile Installation
Electrical Connections
1. Verify that the cold lead wires at the end
of each roll will reach the thermostat
location. Run the cold lead wires no
closer than 1” from the edge of the
warming roll. Cold lead wires cannot
cross over a warming cable or the
sensor wire (if applicable). Please note
thickness of the factory splice and cold
lead and plan accordingly.
One-step method:
1. Use a staple gun, hot glue gun, or
tape to secure the mat meshing to the
subfloor every 6-8 inches. NEVER
staple the wires, only the green mesh.
1. A
pply 3/8” of latex-portland cement with
a square notched trowel over the rolls,
trowelling in the direction of the wires
whenever possible.
1. The electrical wiring should follow the
wiring instructions provided with the
thermostat.
2. Cut the fiberglass mesh backing as
needed. Never cut the heating cables.
Lay out the heating rolls on the floor for
the final dry fitting review.
2. If the system is controlled by a
thermostat, choose a sensor location
within 8 feet of the thermostat box
and not in an area hit by sunshine or
in an uncommonly cold area. Place
the sensor underneath the fiberglass
backed mesh, and center it directly
between the heating wires (See
Diagram 1). It must project at least 6”
into the heated area. The sensor wire
must not cross heating wires, but may
cross the cold leads if necessary.
3. Run all cold lead wires beside the mats
securing them to the subfloor with hot
glue or tape every 8-10 inches in a
flat path back to the control or junction
box location. For even tiles , you may
need to route into the subfloor or
underlayment for clearance of the cold
lead and splice.
4. Perform 2ND ohm test. Connect circuit
check (if purchased) to each heating roll.
Diagram 1
2. S
et tiles as recommended. TIP: Remove
excess thin-set that may ooze up between
the grout joints with a wet rag, toothbrush
or sponge while installing the tile, in
preparation for a clean grout installation.
NEVER use a utility knife to remove cured
thin-set from grout joints as this can easily
damage the heating wires and void the
warranty.
3. D
isconnect Circuit Check and Perform
and record 3RD ohm test on Warranty
Registration Card.
Two-step method:
1. A
pply a 1/8” skim coat with a flat rubber
trowel using latex-portland cement or selfleveling cement over the rolls and allow
proper cure time as per manufacturer
recommendation before moving to next
step.
2. A
pply a second ¼” layer of latex-portland
cement using a square notched trowel and
set tile as recommended. TIP: Remove
excess thin-set that may ooze up between
the grout joints with a wet rag, toothbrush,
or sponge while installing the tile, in
preparation for a clean grout installation.
NEVER use a utility knife to remove cured
thin-set from grout joints as this can easily
damage the heating wires and void the
warranty.
3. D
isconnect Circuit Check and Perform
and record 3RD ohm test on Warranty
Registration Card.
11
2. The thermostat is mounted in a doublegang wall box with a single-gang mud ring.
3. The heating mats must be connected to
the electrical service via a GFCI (Ground
Fault Circuit Interrupter). The GFCI feature
is incorporated in the thermostat.
4. All electrical connections should be
performed by a licensed, certified
electrician.
Allow proper thin-set and grout cure time as
recommended by the manufacturer before
powering-up the WarmlyYours electric
radiant heat system.
Glue Down Laminate & Engineered Wood Floors - Installation Guide
Materials
and Tools Required:
• WarmlyYours TempZone™ Heating Rolls
• Thermostat with Sensor Probe Wire
• Custom Design Layout (provided free with quote)
• Digital Ohm Meter (required for completion of warranty registration card)
• Circuit Check (sold separately)
• Scissors
• Staple Gun or Hot Glue Gun (concrete applications)
• Duct Tape or Box Tape
• Latex-Portland Cement (acrylic or latex modified thin-set mortar)
• Plastic Notched Trowel
• Flat Rubber Trowel (float trowel)
• Self-leveling Cement
• ¼” Cork or 3/16” CeraZorb® concrete insulating underlayment (WarmlyYours offers
both of these products), or similar, is recommended when installing over concrete.
This is recommended to increase efficiency, but is not mandatory.
See Thermal Insulating & Sound Control Underlayment installation
instructions. We do not recommend using self-leveling cement directly over cork
insulating underlayment. However, self-leveling cement can be used directly over
CeraZorb® insulating underlayment.
Preparation:
1. Cross-check the items received against the packing list and the materials list on
the installation plan to ensure that the roll length and thermostat type are an exact
match.
2. Perform 1st ohm test - Measure the resistance of each mat with an Ohm meter
(reading core wire to core wire) and record the readings on the UL label and on
the installation plan. The Ohms readings should be within a +/- 15% variance of
the Ohm value specified on the UL tag. Measure the continuity between core wire
and ground wire – The reading should be O/L or infinity.
3. Prepare the subfloor to be clean and free of debris.
4. Do a dry fit of the rolls on the subfloor according to the custom design/installation
plan. Measure and mark the mats and subfloor if necessary.
5. Make any adjustment in the layout PRIOR to cutting the roll.
6. When using Self-Leveling Underlayment (SLU), we suggest priming the floor
before laying out the rolls. Doing so will ensure that the primer covers the
subfloor completely. Whenever using SLU, ALWAYS follow the installation
recommendations set forth by the SLU’s manaufacturer. It is very important to
adhere the heating roll securely to the subfloor, otherwise the heating wire may
float to the top of the SLU.
Please call WarmlyYours at (800) 875-5285 if the roll does not provide the specified
coverage or for 24/7 installation and technical support.
Concrete Subfloor Applications:
Prepare the subfloor as per flooring manufacturer recommendations. In some cases,
leveling of the subfloor may be necessary. Leveling should be done before installing
heating rolls. Insulating over concrete slab: Adhere the ¼” cork or 3/16” CeraZorb®
insulating underlayment to the concrete with latex-portland cement using a 1/8”
v-notched trowel.
NOTE: Self-leveling cement cannot be poured directly over cork insulating
underlayment.
For applications where self-leveling cement must go directly over the concrete
insulator, we recommend using CeraZorb® insulating underlayment.
12
Glue Down Laminate & Engineered Wood Floors - Installation Guide
STEP 1
Install WarmlyYours
Heating Rolls
1. Install the floor heating system as
recommended, adhering the mesh every
6-8 inches with hot glue (or staples if
using cork insulation), carefully routing the
power leads alongside the system back
to the power supply. Never staple directly
over the wires.
2. Install the thermostat sensor probe
(if applicable) 6” into the heating mat
centered directly between the heating
wires. The sensor wire must not contact
the heating wire. Connect circuit check (if
purchased).
3. Use a flat trowel to encase the heating
rolls in 3/8” of self-leveling cement or
latex-portland cement and allow proper
manufacturer recommended cure time.
Follow manufacturers recommended
mixing directions carefully.
4. Perform 2nd ohm test.
13
STEP 2
Apply the Flooring
Adhesive (glue)
1. Apply manufacturer’s recommended
adhesive as per flooring installation
instructions.
STEP 3
STEP 4
Install Laminate /
Engineered Wood
Flooring
Electrical Connections
1. Install laminate or engineered wood
flooring as per manufacturer’s
recommendations.
2. The thermostat is mounted in a doublegang wall box with a single-gang mud ring.
2. P
erform and record 3rd ohm test on
Warranty Registration Card.
1. The electrical wiring should follow the
wiring instructions provided with the
thermostat.
3. The heating rolls must be connected to the
electrical service via a GFCI (Ground Fault
Circuit Interrupter). The GFCI feature is
incorporated in the thermostat.
4. All electrical connections should be
performed by a licensed, certified
electrician.
Allow proper adhesive & setting material
cure time as recommended by the
manufacturer before powering up the
WarmlyYours electric radiant heat system.
Electrician’s Guide – Trouble Shooting
“Beware of Using a
Continuity Checker!”
Our smaller Heating Rolls have a high Ohm resistance
and some continuity checkers do not send enough
current to get completely through the wire and emit
the noise or light that affirms proper continuity. If your
instrument cannot function on a small Heating Roll,
please use a digital Ohm meter.
Electrical Fault-Finding
Once the system has been turned off and made safe,
have a suitably qualified person:
1. Ensure all wires have been connected as per the
wiring diagrams.
2. Make sure multiple rolls have been wired in parallel
with all leads returning to the thermostat and not
hooked to each other in series.
3. Confirm that control devices are receiving correct
voltage.
Use a well calibrated digital Ohm meter with good
batteries. The Ohm resistance level of each Heating Roll
should be checked and the reading compared with the
resistance that was recorded during installation on the
corresponding UL label(s) (located on the circuit breaker
box) and in the log on Page 16 of this Manual. If your
reading is not within the 15%+/- range from the original
reading, the roll may be damaged in some way. If you get
zero across the core this indicates an open or short circuit
beneath the finished flooring. The electrical contractor
must locate the point of break or short, in coordination
with the Technical Services Department of WarmlyYours.
com.
Locating a Break or a Short
Checking for Electrical Short
If your installation is complete, all wiring connections
have been verified to be correct, including grounding of
the system, you have checked the sensor wire for proper
Ohms reading, and you suspect the system is still not
working; you need to determine if there is a break or a
short under the floor.
In some rare occasions an installation may have suffered
from a high pressure point that broke the insulation between
the core conductor and the multi-stranded sheath. Such an
opening in the insulation layer can create an electrical short,
even though the Ohm reading from the white conductor to
the yellow or red conductor is normal and does not indicate
any circuit break. In these rare occasions a continuity test
will show continuity between the one or both of the core
conductors and the sheath wire.
Checking for Breaks
The Ohm resistance of each roll should be measured
across the core wires.
Make sure the probes of the Ohm meter do not touch the
sheath wire. Make sure you do not touch either of the
probe ends with your fingers, or the meter will be reading
your internal body resistance.
There should be no continuity (=“ infinite” resistance
reading, not zero) between the conductors and the sheath.
If your instrument reveals continuity between the core
conductor and the sheath, there is a short in the circuit.
Make sure your Ohm meter is set on the proper scale (0to- 200 for Heating Rolls, or 0-to-20,000 for the sensor
wire). Your Ohm resistance readings should come within
15% (plus or minus) of the original measurement indicated
by the factory on the UL label.
If your Ohm reading is within 15% of what it should be,
there is no break. However, you still need to check for an
electrical short.
If your Ohm reading is lower (outside the 15% range), but
there is clearly some continuity, check your Ohm meter
and your batteries. If these are good, there is a possibility
that you have several electrical shorts.
Infinity Ohm Reading?
If you have absolutely no reading (= infinity on your
meter), and you are sure you adjusted the setting of the
Ohm meter to the correct reading range (0-to-200 for the
Heating Rolls, or 0-to-20,000 for the sensor wire), then you
have a break (= total cut) in the conductor.
14
Important General Considerations Cont.
Important Information
The most important consideration is to maintain the
integrity of the Heating Element; following these simple
rules can easily do this:
1. NEVER CUT the Heating Element.
2. NEVER CUT the Heating Roll(s) to make it shorter.
3. NEVER fold or position the Heating Element so that it
overlaps itself or other wires. This will cause dangerous
overheating.
4. NEVER run the Cold Lead Wires or Sensor Wire across the
Heating Element.
5. NEVER place built-in cabinets and other furniture with solid
bases on the heated portion of the floor.
Note for the System Installer
Provide the homeowner with a copy of the Installation Plan provided to
you by WarmlyYours.
This will help you and future owners of the home. The plan should indicate where the
WarmlyYours Heating Roll(s) is installed, the location of the control device and the
amperage of the system. If a sensor is used, indicate its location on the plan. The electrician
should put the code labels (UL) from any Heating Roll used in a convenient place such as
the circuit breaker box. The labels should have Ohm resistance readings written on them.
These are a useful reference for future inspections and possible troubleshooting.
Complete the Warranty Card and return to WarmlyYours within 90 days.
Keep your plan and this installation manual safe for future reference.
Record your installation information here:
Name/Company of Electrician_______________________________________________
Address________________________________________________________________
6. ALWAYS make sure the system is inspected and the Ohms
tested before, during and after installation.
Tel.#___________________________________________________________________
7. ALWAYS make sure everyone involved in the installation is
aware of the care needed to protect the Heating Element
from damage.
Name/Company of Floor Installer____________________________________________
8. ALWAYS maintain consistent spacing when positioning the
Heating Element.
Tel.#___________________________________________________________________
9. NEVER connect two Heating Rolls to each other (in series).
Only connect them in parallel to the same control device.
Date of installation________________________________________________________
10. Tiles will only be warm where the heating wire is installed.
If there is no heating wire directly under the area, it will not
be warm.
15
Location of UL labels______________________________________________________
Address________________________________________________________________
Location of Installation Plan_________________________________________________
The instructions in this manual must be observed when installing the WarmlyYours Floor
Heating System. Failure to follow these instructions may inhibit optimal performance of
your Floor Heating System and void the system warranty. A tile-setter, flooring contractor
or qualified Do-It-Yourselfer can install the WarmlyYours Heating Roll(s). However, a
qualified electrician must complete the electrical connections of the system to the main
electrical circuit in accordance with the National Electrical Code and your local codes. We
trust that your installation goes well and that you enjoy your warm floors!
Warranty Information
Please complete and return the Warranty Card (online or you may send/fax this form)
Thank you for purchasing your new WarmlyYours TempZone™ floor warming system. To register your system, go online to www.WarmlyYours.com/warranty, or
simply complete, detach and mail the Warranty Card within 30 days of date of purchase to: WarmlyYours, 2 Corporate Dr., Suite 100, Long Grove, IL 60047. For your
convenience, you may also fax this card to (800) 408-1100.
1. HOMEOWNER INFORMATION
4. HEATING SYSTEM INFORMATION
Company Name
Phone
Address
Email
City
State
Install Date
Installed Under:
oTile
oStone
oLaminate Wood
oOther
(Please specify other) _____________________________
Postal/Zip
Fax
2. FLOOR INSTALLER INFORMATION
Check here if homeowner installed
Company Name
Phone
Address
Email
City
State
Postal/Zip
Fax
Sub Floor Material
Set In
Total Rolls Installed
Roll Size
Final Ohm Reading
Roll 1
Roll 2
3. ELECTRICIAN INFORMATION
Roll 3
Company Name
Phone
Address
Email
City
State
Roll 4
Roll 5
Postal/Zip
Fax
WarmlyYours, Inc. warrants the WarmlyYours TempZone™ electric floor warming system rolls (“the Product”) to be free
from defects in materials and workmanship for 15 years from the date of manufacture, provided that the Product is installed
in accordance with the WarmlyYours product installation guide, any special written or oral design or installation guidelines
provided by WarmlyYours for the specific project that the Product is intended, the provisions of the National Electric Code
(NEC), and all applicable local building and electrical codes. If the Product is determined to be defective in materials and
workmanship, and has not been damaged as a result of misuse, misapplication or improper installation, WarmlyYours will
reimburse the cost for location of the fault, repair of Product, and any labor and materials required to perform the repair. If
repair of the Product is not feasible, WarmlyYours will replace the Product or refund the original cost of the Product. Controls
sold under the WarmlyYours name are warranted for specific coverage periods. Please see www.WarmlyYours.com for the
length of warranty coverage for each control. Should the control be defective or malfunction, return the control to WarmlyYours
and it will be repaired or replaced (at WarmlyYours option). The warranty does not cover removal or reinstallation costs. See
entire warranty in packaging.
WarmlyYours Inc. assumes no responsibility under this warranty for any damage to the Product prior to or during installation by
anyone, including, but not limited to trades people or visitors to the job site, or damage caused as a result of post installation
work. Call our toll free number, (800) 875-5285, if you have any questions about installation. The Limited Warranty is null and
void if the Product owner or his representative attempts to repair the Product without receiving authorization. Upon notification
of an actual or possible problem, WarmlyYours will issue an Authorization to Proceed under the terms of the Limited Warranty.
Warranty Subject to the Following Conditions: 1. The warranty of the warming system must be registered by completing and
returning the attached ‘System Warranty Registration’ card to WarmlyYours, Inc. within thirty days of date of purchase. Please
keep your invoice, as proof of date of purchase will be required in the event of a claim. 2. The warming roll must be installed
flat under tile, stone, resilient flooring or laminate wood in a latex modified thin-set or a portland-based cement. 3. The warming
system must be electrically grounded and protected by a GFI (Ground Fault Interrupter). 4. The installation must comply with
all national and local electrical and building codes, as well as any other applicable statutory requirements. 5. The manufacturer
hereby reserves the right to inspect the installation site at any reasonable time. 6. The warranty is not automatically transferred
Roll 6
Roll 7
with change of ownership, but the manufacturer may, on application, transfer the warranty for the period remaining. This
transfer is solely at the discretion of the manufacturer. 7. The warming system should be used strictly in accordance with the
following: 7.1 Hard wire the warming system rolls to a dedicated circuit. The voltage of the circuit should match the voltage of
the warming system, and the size of the circuit should be such that the warming system does not occupy more than 80% of
the circuit capacity. 7.2 Should you feel no warmth on the floor within 60 minutes, verify that there is power to the control or
thermostat. Contact WarmlyYours after verifying that there is power through the load wires. Under no circumstances should
you or anyone else tamper with or attempt to repair the warming system - this will render the warranty null and void. 7.3 Switch
the warming system on and off as you would any conventional electric heater, although timers or thermostats may be used if
preferred. 7.4 Use reasonable care in the operation of the warming system. Do not drop heavy articles on the flooring or pierce
the flooring with sharp objects. 7.5 All restrictions and warnings detailed in the installation guide must be strictly followed.
WARMLYYOURS, INC. DISCLAIMS ANY WARRANTY NOT PROVIDED HEREIN, INCLUDING ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. WARMLYYOURS
FURTHER DISCLAIMS ANY RESPONSIBILITY FOR SPECIAL, INDIRECT, SECONDARY, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES ARISING FROM OWNERSHIP OR USE OF THIS PRODUCT, INCLUDING INCONVENIENCE
OR LOSS OF USE. THERE ARE NO WARRANTIES, WHICH EXTEND BEYOND THE FACE OF THIS DOCUMENT. NO
AGENT OR REPRESENTATIVE OF WARMLYYOURS HAS ANY AUTHORITY TO EXTEND OR MODIFY THIS WARRANTY
UNLESS A CORPORATE OFFICER MAKES SUCH EXTENSION OR MODIFICATION IN WRITING.
WarmlyYours makes no claim as to the amount of floor/room temperature rise, the time to reach a given floor/room temperature
or final floor/room temperature due to the innumerable variations in building construction and environmental conditions.
RETURN POLICY
Product will be accepted for return if it is in “resalable” condition. The product must be in exactly the same condition as when
we shipped it to you.
30000-I 8/2012
16
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