WarmWire ® Installation Manual Series WB & WR Assembled in the USA 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 6 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.
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 given are for use with CableStrap only. Contact the factory if using alternate attachment materials that may require different wire spacing. 120 VAC Model Number 120010 120015 120020 120025 120030 120035 120040 120045 120050 120060 120070 120080 120090 120100 Total Sq. ft. 2.5" Spacing 14.4 watts/ft2 8 13 17 21 25 29 34 38 42 51 59 67 76 84 Total Sq.
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.
Phase 3 - Install the Cables STEP 3.1: 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 3.
If using an attachment membrane like Schluter® DITRA-HEAT Membrane or RPM mat, go to Step 3.8. Install CableStrap STEP 3.5 Measure the edge of the Heated Area where CableStrap will be installed. 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.
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. Install Cable Attachment Membrane STEP 3.8 If using Schluter ® DITRA-HEAT Membrane or RPM mat, read and follow completely the installation instructions given with that product.
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. Installing Cables on Attachment Membranes STEP 3.14 Weave the cable back and forth across the area at the desired spacing. Maintain slight tension on the cable to ensure it does not pull loose. If desired, use hot glue at intervals to help ensure it stays secure. NEVER space the cables less than approximately 2.5" apart.
area at the desired spacing, then install a single run down the riser. Use an "s-shaped" curve to avoid sharp bends in the cable at corners and help the cable to lay flat. Again, the cable on the riser and seat area MUST be fully embedded in mortar and have approved floor coverings. Use hot glue where necessary to secure the cable flat against the riser. Shower area installation This application into a shower area must be verified by the local inspector or the authority having jurisdiction (AHJ). STEP 3.
STEP 3.24 If covering a shower floor, cut lengths of strap and secure to the floor with adhesives. Do not use fasteners that penetrate any waterproofing membrane or waterproofing system. Fill in the floor area with cable. Around the drain leave at least 2" spacing from the edge of the flange. Make sure cable is not placed where door hardware, handrails, or other items may mount to the floor. STEP 3.
Phase 4 - Finish Wiring STEP 4.1 STEP 4.3 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 4.2 Below the control, or wherever the floor sensor is to be located, measure at least 1 ft.
Phase 5 - Control Installation STEP 5.1: 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 5.2 Refer to the wiring diagrams in the Appendix of this manual for typical configurations. STEP 5.3 Read and follow the instructions included with the SunStat thermostat and SunStat Relay for complete connection instructions, requirements, and mounting. STEP 5.
Phase 6 - Floor Coverings / General Recommendations Please note, this installation manual is not a structural or a floor covering installation manual and is intended only for general guidance as it applies to the SunTouch WarmWire product. It is recommended to consult with professional flooring installers to make sure proper materials are used and proper installation techniques are followed.
Phase 7 - Install Insulation Insulate under the subfloor for better performance and efficiency of the system. Refer to the Appendix for diagrams and insulation recommendations. Appendix 1: Types of Construction and Applications Type of Construction Mortar Applications: Thin-set and thick-set (self-leveling) mortar applications are illustrated to the right. 1.
Double-plywood over frame floor Tile/stone or laminate flooring Latex-Portland cement mortar bond coat Heating cable Plywood Plywood subfloor Insulation (per International Residential Code, Chapter 11) Joist 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/sto
Appendix 2: Wiring Diagrams 120/240VAC Control Wiring Diagrams Typical Wiring for one WarmWire cable with SunStat thermostat (120/240VAC) 20-amp circuit. Ground 120/240 VAC SunStat® Control Load 1 Black Line 1 Black Black Sensor Wire (no polarity) Sensor 120 VAC or 240 VAC Bus Line 2 White White A B Load 2 White WarmWire Cable 120 VAC or 240 VAC Heating Cable (maximum 15 amps) Typical Wiring for multiple WarmWire cables with SunStat thermostat (120/240VAC) 20-amp circuit.
SunStat Relay Connection Diagrams Typical Wiring for SunStat with SunStat Relay(s) 20-amp circuit for each SunStat and SunStat Relay Ground 120/240 VAC SunStat® Control Load 1 Black Black Line 1 Black Sensor WarmWire Cable 120 VAC or 240 VAC Bus White Line 2 White WarmWire Cable Two or more 120 VAC or 240 VAC Heating Cables (maximum 15 amps) A B Load 2 White Use size 18- to 24-gauge 2 conductor wire up to 100 feet (30 m) in length to connect SunStat to SunStat Relay.
Diagram for connection of signal wire between SunStat Control and Relays 120/240 VAC SunStat Control 120/240 VAC SunStat Relay II 120/240 VAC SunStat Relay II Up to 10 SunStat Relay II can be connected to one SunStat Control Sensor Observe polarity when connecting relays All electrical work must be done by a qualified licensed electrician in accordance with local building and electrical codes, and the National Electrical Code (NEC), especially Article 424 of the NEC, ANSI/NFPA70 and Section 62 of CEC
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 rings 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. 24 ft. of strap, or one 25-ft. roll.
Master Bathroom (normal heat loss, framed floor construction) One zone, 120 volts: One cable. 49 ft. of CableStrap, or two 25-ft. rolls. Floor Sensor Va n counter open to floor it y Control CableStrap Toilet Install cables at least 6” away from toilet rings Closet 1 spool 90 ft2 3” spacing Cable end Bath Tub Master Bathroom (normal heat loss, framed floor construction) One zone, 120 volts: One cable. 11 ft. of CableStrap, or one 25-ft. roll.
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.
Recreation Room (high heat loss, below grade basement slab) One zone, 240 volts: One cable. 69 ft. of CableStrap, or three 25-ft. rolls. Control Floor Sensor Cable end CableStrap 1 spool 168 ft2 2.
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 Appendix 2. 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 1453 Watts Radiant Customer Support USA Toll-free: (800) 276-2419 USA Fax: (417) 864-8161 WattsRadiant.
