WarmWire ® Installation Manual Series WB & WR Please be aware local codes may require this product and/or the thermostatic control to be installed or connected by an electrician.
Read this Manual BEFORE using this equipment. Failure to read and follow all safety and use information can result in death, serious personal injury, property damage, or damage to the equipment. Keep this Manual for future reference. WarmWire® is a simple, economical way to warm any floor, and provide years of lasting comfort. This instruction manual provides complete details, suggestions, and safety precautions for installing this floor-warming system. Fasten the cables to the floor.
Expected floor temperature Heating performance is never guaranteed. The floor temperature attainable is dependent on how well the floor is insulated, the temperature of the floor before start up, and the overall thermal drain of the floor mass. Insulation is required for best performance. Refer to Phase 9 for important design considerations. These are the three most common installations: 1.
Table 1 As with any electrical product, care should be taken to guard against the potential risk of fire, electric shock, and injury to persons. The following cautions must be observed: NEVER install WarmWire under carpet, wood, vinyl, or other non-masonry flooring without embedding it in thin-set, thick-set, or self-leveling mortar. NEVER install WarmWire in adhesives or glues intended for vinyl tile or other laminate flooring, or in pre-mix mortars. It must be embedded in cement based mortar.
ALWAYS make sure all electrical work is done by qualified persons in accordance with local building and electrical codes, Section 62 of the Canadian Electrical Code (CEC) Part I, and the National Electrical Code (NEC), especially Article 424. ALWAYS use copper only as supply conductors to the thermostat. Do not use aluminum. ALWAYS seek help if a problem arises.
Table 2 - Cable sizes (all Models with suffix WB & WR) Please check the product label for exact ratings. This table is for reference only. The coverage areas below are for CableStrap or HeatMatrix installation. Contact the factory if using alternate attachment materials that may require different wire spacing. The area coverages shown are approximate and may vary due to installation pattern variations. Also, the heating cable is designed to operate 3 W/linear foot.
To prevent the risk of personal injury and/or death, make sure power is not applied to the product until it is fully installed and ready for final testing. All work must be done with power turned off to the circuit being worked on. STEP 1.1 Remove the WarmWire, SunStat thermostat, and SunStat sensor from their packages. Inspect them for any visible damage. Verify everything is the correct size and type according to the plan and the order. Do not attempt to install a damaged product. STEP 1.
Table 4 - Cable and Sensor Resistance Log Cable 1 Cable 2 Cable serial number Cable model Cable voltage Factory cable resistance range OUT OF THE BOX BEFORE INSTALLATION (OHMS) Cable black to white (black to blue for 240VAC) Cable black to ground Cable white to ground (blue to ground for 240VAC) Sensor wire AFTER CABLE AND SENSOR ARE FASTENED TO FLOOR (OHMS) Cable black to white (black to blue for 240VAC) Cable black to ground Cable white to ground (blue to ground for 240VAC) Sensor wire AFTER FLOOR COVER
Phase 2 - Electrical Rough-in To prevent the risk of personal injury and/or death, make sure power is not applied to the product until it is fully installed and ready for final testing. All work must be done with power turned off to the circuit being worked on. STEP 2.1: Circuit Breaker (Overcurrent Protection) WarmWire must be protected against overload by a circuit breaker.
STEP 2.3: Bottom Plate Work Drill or chisel holes at the bottom plate as indicated. One hole is for routing the power lead conduit and the other is for the thermostat sensor. These holes should be directly below the electrical box(es). Power lead conduit Wire Clip Sensor wire If going in to an existing wall, cut out dry wall and chisel out bottom plate to route wires to control. Power lead Sensor wire STEP 2.
There are 2 installation methods for securing WarmWire: • HeatMatrix offers an easy way to install WarmWire while providing crack-isolation, vapor management and waterproofing for installations with tile or stone. To install, WarmWire is simply pressed into the HeatMatrix channels at a selected spacing. With HeatMatrix, the space between rows can be easily adjusted to accommodate additional wire or provide more or less heat in defined areas.
STEP 3.6: Make sure the cable fits Check the cable size to ensure it will fit inside the Heated Area at the selected wire spacing (see Table 2) The heating cable CANNOT be cut to fit. It must be kept its original length and fully embedded in the mortar in the floor. Any modification or mis‐use of the heating cable will void the warranty and cause potential shock or fire hazard. STEP 3.7: Decide the cable layout Decide which direction the cables will run on the floor for the easiest coverage.
WarmWire spacing in HeatMatrix: • Install WarmWire with 3-shapes in-between each row for approx. 12.3 W/ft2 heat output (standard spacing) • Alternate between 3-shapes and 2 for a higher heat output of 14.8 W/ft2 • Alternate between 3-shapes and 4 for a lower heat output of 10.6 W/ft2 3 3 3 2 = 12.3 W/ft2 3 = 14.8 W/ft2 3 = 10.6 W/ft2 3 4 3 STEP 3.10 Bench seat If covering a bench seat or step area (not in a shower area), place a single run of cable up the riser.
Phase 4 - Cable Installation with CableStrap™ STEP 4.1: Floor Cleaning The floor must be completely swept of all debris including all nails, dirt, wood, and other construction debris. Make absolutely sure there are no objects on the floor which might damage the wire. Wet mop the floor at least twice to ensure there is no dirt or dust. This will allow proper bonding of the mortar and proper stick of any adhesives or double-sided tape used later. STEP 4.
Install CableStrap STEP 4.5 Measure the edge of the Heated Area where CableStrap will be installed. STEP 4.6 Cut the CableStrap to length using metal shears. Concrete, self-level, or similar: Double-sided tape (if included with your cable), hot glue, or strong spray adhesive may be used if the floor is well cleaned and the strap is wiped free of any oils. However, it is highly recommended to also place screws at each end of the strap, and every 4 to 5 feet, to ensure it does not come loose.
Completely embed the Factory Splice and heating cable in the floor mortar. Never bend the factory splice. Never allow any part of the Factory Splice or heating cable to enter a wall or cabinet or drop through the subfloor. Damage to the product will result. Position the Power Leads & Factory Splice STEP 4.8 Carefully cut the tie binding the power lead coil. Do not nick the braid covering the power lead.
STEP 4.12 To secure long lengths of heating cable, place additional, short lengths of the strap at 3–4-ft. intervals. Spray the back of the strap with a high-tack adhesive, and slide the strap, upside down, under the cables. Turn the strap over when it is positioned and adhere to the floor. Press the tabs down over the cables. If a spray adhesive was not used, carefully secure these short lengths of strap to the floor without damaging the cable. Install second cable STEP 4.
Phase 5 - Shower Area Installation This application into a shower area must be verified by the local inspector or the authority having jurisdiction (AHJ). STEP 5.1 Cables only with (-W) on the nameplate label may be installed into a floor or bench seat located in a shower area. It must never be installed into walls. In general, the cable should be completely embedded into mortar as close to the surface coverings as possible.
A (-W) on the nameplate label indicates a WarmWire cable is approved for installation in shower floors and/or benches. SunStat Thermostat Factory Splice Floor Sensor Thin Set Mortar WarmWire Tile/Stone STEP 5.5 If covering a bench seat in the shower with cable, secure it with hot glue or with HeatMatrix or CableStrap located underneath waterproofing. Do not use fasteners that penetrate any waterproofing membrane or waterproofing system.
Phase 7 - Finish Wiring STEP 7.1 STEP 7.3 Feed the power leads from the cable up through the hole drilled in the baseplate, or up into the conduit to the control electrical box (or junction box if one was used). To make sure the sensor tip does not create a high spot in the floor, it may be necessary to chisel a channel into the floor and lay the sensor tip into the channel. Hot glue the tip into place. STEP 7.2 Below the control, or wherever the floor sensor is to be located, measure at least 1 ft.
Phase 8 - Control Installation STEP 8.1: If it has not already been done, install an electrical box for the SunStat® thermostat and SunStat Relay. See Step 2.2 for details. STEP 8.2 Read and follow the instructions included with the SunStat thermostat and SunStat Relay for complete connection instructions, requirements, and mounting. STEP 8.3 Make any final connections to the circuit breaker or branch circuit source.
Do not use solvent based adhesives or pre-mix mortars because they are not as heat resistant and do not conduct heat well. • When installing over HeatMatrix, read and follow the instructions given with the HeatMatrix product. Apply the mortar by filling all voids in the HeatMatrix with the flat side of the trowel, then comb to ensure 100% coverage. Avoid lining up tile grout lines with joints between sections of HeatMatrix. • Select the proper size trowel for the installation of tile or stone.
Appendix 1: Minimum Clearances for WarmWire Minimum Clearance 1" 3" 3" 3" 6" 2" 1" 1" 3" 1-1/2" 2" Bathroom vanity or kitchen cabinet toe-kick Showers or tub boundaries Doorway framing Walls Toilet flange Other heating wire Heating cable power lead Appliances (washer, dryer, oven) Baseboard heaters or radiators Below a built-in,cabinet,furniture Drains Do not install WarmWire in closets, pantries or in other small enclosed spaces.
Mortar Applications with CableStrap: 1. If a backer board or plywood sheeting is used to strengthen the floor, or if the heating wire will be placed directly onto the slab, install WarmWire in the thin-set mortar bond coat above these materials. 2. If a thicker mortar bed, or self-leveling concrete, is used to strengthen the floor, the heating wire can be installed in either the mortar bed (dry-set) or in the mortar bond coat directly below the tile or stone.
Cement backerboard over frame floor Tile/stone or laminate flooring Latex-Portland cement mortar bond coat Heating cable Cement backerboard, thick-set, or self-leveling mortar bed Plywood subfloor Insulation (per International Residential Code, Chapter 11) Joist Thin-set over slab on grade Tile/stone or laminate flooring Thin-set or self leveling mortar bed Heating cable Antifracture membrane or cork underlayment, as needed Concrete slab with rewire or rebar Insulation beneath slab (per International
Connecting Multiple Cables To prevent the risk of personal injury and/or death, do not perform any electrical work unless qualified to do so. Work should be done with great care and with power turned off to the circuit being worked on. Follow all local building and electrical codes.
Appendix: Sample Layouts Kitchen and Family Room (normal heat loss, slab on grade with insulation) Two zones, 240 volts: Three cables. 190 ft. of CableStrap, or eight 25-ft. rolls. CableStrap Cable end 1 spool 240 ft2 3.
Kitchen and SunRoom (normal and high heat loss, framed floor construction) One zone, 240 volts: Two cables. 104 ft. of CableStrap, or five 25-ft. rolls. Cable end Ra Pantry e ng Counter/cabinetry Counter and cabinetry Microwave CableStrap 1 spool 120 ft2 3” spacing Control Floor Sensor 1 spool 118 ft2 2.
Master Bathroom (normal heat loss, framed floor construction) One zone, 120 volts: One cable. 35 ft. of CableStrap, or two 25-ft. rolls. Toilet Bath Tub Install cables at least 6” away from toilet flange 1 spool 100 ft2 3” spacing CableStrap Cable end Vanity Control Floor Sensor Vanity counter open to floor Master Bathroom (normal heat loss, framed floor construction) One zone, 120 volts: One cable. 49 ft. of CableStrap, or two 25-ft. rolls.
Basement Bathroom (high heat loss, below grade basement slab) One zone, 120 volts: One cable. 39 ft. of CableStrap, or two 25-ft. rolls. 1 spool 59 ft2 2.
Master Bathroom (normal heat loss, framed floor construction) Two zones, 120 volts: Two Cables Shower Zone 1b Cable End Bath Tub Shower Curb Cable End CableStrap Zone 1a Floor Sensor Control Vanity Toilet Install cables at least 6” away from toilet rings Example of Cables only with (-W) on the nameplate label, where cable is installed in a shower area and enters over the curb.
Installing WarmWire above the waterproof liner WarmWire can be installed above the waterproofing liner if the attachment method does not puncture the liner. A overlay of thinset is first applied over the liner. CableStrap or 2-inch HeatMatrix strips are then attached to opposite sides of the shower using hot glue or double sided tape. Leave a 2 inch gap between the drain flange and WarmWire. When using HeatMatrix, strips are covered with mortar and Joint Tape after the wire is in place.
Troubleshooting Guide If not qualified to perform electrical installations, it is strongly recommended that a qualified, licensed electrician be hired to install the heating cables and related electrical components. If problems with the system arise, please consult the troubleshooting guide below. Any electrical troubleshooting work should be performed with the power removed from the circuit, unless otherwise noted.
Problem Floor heats continuously. Control is not working correctly. Control is not working at all. GFCI conflicts and false-trips. Possible Cause Solution Incorrect wiring. The control was “bypassed” when it was wired to the power supply. Make sure wiring connections are correct. Consult the wiring diagram on the back of the control, the instructions that came with the control, or the wiring diagrams in the Appendix. Defective control. Return control to dealer for replacement.
Electric Floor-warming Products 25-year Limited Warranty SunTouch and Watts Radiant (the Companies) warrant their respective electric floor heating mats and cables (the Products) to be free from defects in materials and workmanship for twenty-five (25) years from the date of manufacture. Thermostats and controls sold by the Companies are warranted, parts and materials, for two (2) years from the date of purchase. The sole remedy for controls is product replacement.
Affiliations: SunTouch Customer Support USA Toll-free: (888) 432-8932 USA Fax: (417) 831-4067 Canada Toll-free: (888) 208-8927 Canada Fax: (905) 332-7068 Latin America Tel: (52) 81-1001-8600 Latin America Fax: (52) 81-8000-7091 SunTouch.com The SunTouch and Watts Radiant manufacturing facility’s Quality System is an ISO 9001:2008 registered facility through LRQA. 8 40213 19790 IOM-WR-WW 1616 Watts Radiant Customer Support USA Toll-free: (800) 276-2419 USA Fax: (417) 864-8161 WattsRadiant.
