Electric Snow Melting Mats and Cables Installation Manual Please note that local codes may require this product and/or the control to be installed or connected by an electrician
Welcome to ProMelt Electric Snow melting SunTouch ProMelt products are a simple way to eliminate snow and ice from surfaces. This instruction manual is provided as a guide to installing ProMelt Mat and ProMelt Cable, including design considerations, mat and cable installation, control installation, precautions, and surfacing guidelines.
Table of Contents Phase 1 Designing the System------------------------------------------------------------------------------------- page 05 Phase 2 Preparations------------------------------------------------------------------------------------------------- page 10 Phase 3 Installing the Mat or Cable------------------------------------------------------------------------------- page 12 Phase 4 Finish Surfaces---------------------------------------------------------------------------------------------
Some Typical ProMelt Installations Garage ProMelt works well for stairs and ramps. Driveway with full coverage near garage and "tire track" coverage down driveway. Entry Entry Garage Garage ProMelt Mats and Cables can be used in combination to fit a variety of areas.
Phase 1: Designing the System STEP 1.1 Determine general areas where you want to install ProMelt Mat/Cable Applications include driveways, walkways, patios, permanent ramps, masonry steps and benches, shipping docks, under garage door seals and more. Anywhere outdoors in residential or commercial locations where snow or ice accumulate may be considered, as long as ProMelt is completely embedded in concrete, sand, thick mortar bed, or asphalt.
STEP 1.4 (ProMelt Mat Only) Select the ProMelt Mat(s) you need. (for ProMelt Cable sizes see next page) WATTAGE: Decide what heat output is required. Your design must consider weather conditions and how critical it is to clear the heated area. Mat with 50 watts per square foot heat output are sufficient to clear most moderate and heavy snowfall rates. Mat with 38 watts per square foot heat output are sufficient to clear most light to moderate snowfall rates.
STEP 1.4 (ProMelt Cable Only) Select the cables you need. WATTAGE: Decide what heat output is required. Your design must consider weather conditions and how critical it is to clear the heated area. 50 watts per square foot: sufficient to clear most moderate and heavy snowfall rates 38 watts per square foot: sufficient to clear most light to moderate snowfall rates SIZE: Select a cable in Table 2 to fit the Heated Area measured in Step 1.2. ProMelt Cable is manufactured in a variety of sizes as shown.
STEP 1.5 (ProMelt Cable only) If the cable is to be laid on top of an existing slab, select enough Cable Strap to secure the cable to the surface. One box contains 25 ft. of strap, enough to secure about 50 sq. ft. of cable at 4-ft parallel spacing. Cable strap is usually spaced no more than 3 to 4 feet apart. STEP 1.6 Select the controls and sensors for your ProMelt Mats/Cables. Various types of controls may be used.
•• Circuit breaker size and circuit wiring should be designed to 125 percent of heating mat load: -20 amp circuit for load up to 16 amps -30 amp circuit for load up to 24 amps -40 amp circuit for load up to 32 amps -50 amp circuit for load up to 40 amps -70 amp circuit for load up to 50 amps •• Follow NEC, CEC, and local code guidelines for branch circuit wiring, conduit, and junction box installations.
Phase 2: Preparations Before installing ProMelt, make sure to fully check out the products, and carefully plan your site. The following steps may not necessarily occur in the order shown, depending on contractor and electrician scheduling and variations in site preparation requirements. A good discussion with all parties involved will help eliminate costly errors and damages. INSPECT MAT/CABLE, CONTROL, and SENSOR STEP 2.1 Remove the ProMelt Mat/Cable, control, and sensor from their packages.
Table 3 - Mat/Cable Resistance Log Mat 1 Mat 2 Mat 3 Mat/Cable serial number Mat/Cable model number Mat/Cable voltage Mat/Cable resistance range OUT OF THE BOX BEFORE INSTALLATION Mat/Cable white to white Mat/Cable white to ground Mat/Cable white to ground AFTER MAT/CABLE IS SECURED IN PLACE Mat/Cable white to white Mat/Cable white to ground Mat/Cable white to ground AFTER COVERINGS ARE APPLIED Mat/Cable white to white Mat/Cable white to ground Mat/Cable white to ground Retain this log to retain the
STEP 2.9 Paver or Stone Applications Follow guidelines recommended by the paver manufacturer. If a coarse of sand is to be applied over the gravel base, the mat/cable must first be secured in place and then covered with a minimum 1-1/2 inch layer of sand to completely embed the mat. STEP 2.10 Ceramic or Stone Tile Applications ProMelt mats or cables can be installed in the structural slab or in a thick mortar bed above a structural slab.
or the asphalt to completely cool. Therefore, if using ProMelt Cable, you may want to lay it out and tie it to rewire that can be quickly lifted into place after the first is laid. This might also be preferable for a mat installation, although if mats are precut and shaped to the area, they generally can be rolled into place fairly quickly. If a slab sensor is installed in this second layer, plan ahead so this does not cause the first layer to cure or cool too much.
at either end of the heated area, and additional straps should be applied every 3 to 4 feet in between to hold the cable in place during surfacing. STEP 3.6 Stone or Paver Application ProMelt Mat: Begin laying out the mat and secure it onto the base with landscape fabric stakes or similar over the mat tape every 2 feet or so. Make sure it is laid flat. Do not use metallic stakes or staples directly over the heating cable. Be careful not to damage the heating cable.
STEP 3.9 Use a digital multi-meter to measure the resistance between the conductors of the mat/cable power leads again. Record these resistances in Table 3 under “After mat/cable is secured in place”. STEP 3.10 Feed the power leads through the conduit into the junction box, leaving at least 6 inches of free lead length. Secure the heating cable and splice so that they will not be pulled into the conduit.
STEP 3.14 Expansion Joints: ProMelt heating cable must never be run through an expansion joint. Doing so may cause damage to the cable with slab movement. It is recommended to lay the mat so these joints are avoided. However, if it is necessary, a portion of the heating cable may be dropped into the grade below the expansion joint as shown. Fill around the cable with at least 1 inch thick sand.
STEP 4.2 Concrete Application Pour concrete over the base and ProMelt Mat/Cable so that no less than 1-1/2 inches and no more than 3 inches covers the top of the heating cables. The slab should be a minimum of 4 inches thick total. Driveways normally require thicker. Follow building code requirements for required thicknesses. CAUTION: Do not use sharp tools which could damage the ProMelt. Blunted shovels should allow you to work the concrete carefully into all areas.
Step 4.5 Ceramic or Stone Tile Applications For either application below, exterior-grade materials should be selected and installed per manufacturer’s recommendations. Only vitreous tile (non-porous) tile should be used as other tile will absorb moisture which will lead to failure. The maximum thickness above the cable should be no less than 1.5 and no more than 2.5”. A movement joint should be installed between any heated and non-heated area.
Troubleshooting 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 troubleshooting work should be done with the power removed from the circuit, unless otherwise indicated. Call the factory for further assistance.
Appendix: Typical Wiring Diagrams Following are examples of typical wiring connections for the ProMelt systems. Carefully read and follow the instructions given with each control for complete information. All electrical work must be performed by a qualified personnel, in accordance with local codes, ANSI/NFPA 70(NEC Article 426) and section 62 of the CEC part 1.
Maximum 100A Heating Load 120/208/240VAC 2 circuits Pole-mount sense Circuit Breaker Panel Contactor Control CP-100 Maximum 70A breakers Type GFCI class B Ground L1 T1 L2 120 /208 / 240 VAC S1 S2 PM-224 or PM-824 Y2 T2 C1 L1 L2 / N Ground Ground L1 T1 Ground L2 120 /208 / 240 VAC Pole-Mounted Sensor L1 Bl Yel T2 Gr Yel Br C2 S1 S2 L2 / N Junction Box Y2 Ground Ground Ground Use size 18- to 24-AWG 4-conductor wire, outdoor rated (telephone wire).
4500 E. Progress Place Springfield, MO 65803 Phone: (417) 522-6128 Toll Free USA, Canada: (888) 432-8932 On the Web: www.suntouch.com ©2009 Watts Radiant Inc.
