How to Repair In-Floor Heating

Thank you so much for joining us today. My name is Scott from WarmlyYours, and this is my colleague Anatoly. We appreciate you being here for our webinar on how to repair in-floor heating systems. Many of us have been in this business for quite a while, and when I first started, the process of repairing in-floor heating was quite a mystery. It seemed that no one wanted us to know how to do it. However, we realized that sometimes things happen in the field, and it's essential to be equipped to fix any issues that arise. That's why we're addressing this topic today. We all make mistakes, and it's crucial to ensure we can resolve our problems effectively.

As we move forward, I want to encourage you to ask questions throughout the webinar. If you have any thoughts or inquiries, please feel free to type them into the white box on the left side of your screen, and we will be glad to address them. Now, let's take a look at signs of floor heating damage. Anatoly, could you share some indicators that the floor might have been damaged during installation?

The most significant sign you might notice is a GFI message on your thermostat or controller device. Additionally, the breaker may trip, or the floor simply may not heat at all. Both of these conditions can be easily tested with a digital ohm meter to determine the exact issue with the system, whether it's a short or a break. A common way wires can be damaged is through nicks from sharp trowels during installation or while cleaning grout lines with sharp blades. We always recommend using a circuit check and ohm meter throughout the installation process. This practice helps ensure that the system remains undamaged at every stage.

The circuit check is a valuable monitoring device that allows you to continue with the installation while it alerts you to any problems in the line. The ohm meter is another essential tool that provides the exact resistance values of your system, ensuring it remains within the specified range. It's also important to be aware of cold and hot spots, which can indicate incorrect installation. These issues can lead to wire overheating and damage when wires are placed too closely together.

Thermal imaging is an excellent method for troubleshooting these problems. As shown in the thermal picture, you can see instances where there is no damage, but rather an incorrect installation. In this case, the wires are too close together, resulting in cold sections on either side of the floor. This visual representation highlights the importance of proper wire placement during installation.

Now, let's discuss what is included in the troubleshooting kit that you can obtain from us. The kit contains several essential tools: a Hypot tester, a Variac Transformer, also known as a variable AC transformer, which allows you to adjust voltage from zero to 120 volts. Additionally, it includes a cable fault finder, commonly referred to as a short stop, and a digital multimeter, which is readily available at most big box stores. In fact, 90% of your troubleshooting can be accomplished with this simple device, often costing under $20. We also provide a thermal camera, which can be rented from us if you can't find one locally.

Moving on to the ohm meter, it is a critical tool for successful troubleshooting. The first step is to test the floor to determine if there is any short circuit present. To conduct this test, you measure the resistance between each of the core wires and their respective ground. You want to ensure there is no resistance or continuity, as this would indicate a short circuit. The third test involves measuring the resistance across the red and black wires, which are your main heating conductors. If the resistance aligns with the label on the mat, you're in good shape. However, an open reading indicates damage or an open circuit.

One of the advantages of our product is that it features color-coded wires within the cold lead. For instance, if you see red and black wires, that indicates 240 volts, while yellow and black signify 120 volts. If you're troubleshooting a floor with multiple mats and notice a mismatch in wire colors, that could indicate a voltage issue.

In the troubleshooting process, we often use a device called the short stop, also known as a cable fault finder. This device measures the distance from the point you're testing to the location of the break in the cable, whether it's a short or an open circuit. When using the short stop, you first set it to the appropriate setting for the size of the mat you are working with. The operation is straightforward: twist the two conductors together, connect them to one probe, and the ground to the other. The reading will indicate the distance to the break in feet.

However, the short stop is most effective when you have an installation plan to reference. If the installer deviated from the plan, it can complicate the troubleshooting process. For example, if you receive a reading of 38 feet but know that there is some wire length inside the wall, you can subtract that from the total to narrow down the search area. If you don't have a plan, the short stop can still provide a ballpark estimate of where to look.

Next, let's discuss how to identify the exact location of the problem using the troubleshooting kit. The great thing about this kit is that it allows you to pinpoint the issue accurately. It won't just suggest a general area; it will indicate the exact spot in the floor that requires repair.

The troubleshooting kit is high-voltage equipment, and we always recommend that a licensed electrician use it. The Hypot tester sends high-voltage sparks down the wire to the damaged area, creating a hotspot underneath the floor, which can be detected using a thermal camera. However, you should only use the Hypot tester if you don't already have a short circuit present. If a short exists, using high voltage could exacerbate the problem.

In cases of a short circuit, we utilize the Variac, which allows us to supply a lower voltage to the affected conductor. This method helps us identify the location of the short without causing further damage. By applying a lower voltage, we can heat the short circuit to a point where it becomes detectable with a thermal camera.

Once we identify the exact location of the short, we can mark it for repair. It's important to triangulate the spot using tape on adjacent tiles, as this will help you avoid damaging other tiles during the repair process. After removing the tile, you can use the thermal camera again to locate the cable and mark its position for the repair.

When preparing for the repair, the first step is to cut out the damaged portion of the wire. You want to ensure that all damaged or burnt sections are completely removed. After that, you'll need to strip the protective casing of the wire to access the core wires for reconnection.

It's essential to note that in some municipalities, this work must be performed by a licensed electrician. We always recommend hiring a professional due to the high voltage involved. If you need to pinpoint a break in the wire, the tools we've discussed will help you do that effectively.

Once you've prepared the wire, the next step is to use a splice kit, which includes all the necessary components for a successful repair. Start by sliding the larger heat shrink tube onto one side of the wire. This piece will be used to cover the repair once it's complete, ensuring a waterproof seal.

The first piece you put on is the last piece you'll use, so it's crucial to remember this step. After removing the protective casing, you'll separate the inner conductors and the ground sheathing. The exposed conductors will be joined using crimp solder connectors provided in the splice kit.

It's important to use a blade rather than a wire stripper for this process, as the wires may vary in thickness. After crimping the connectors onto the wires, you'll need to apply heat to the solder inside to ensure a secure connection.

When applying heat, make sure to do it evenly around the wire to ensure a proper seal. The adhesive inside the heat shrink will provide waterproofing and insulation for the repair.

If you're unsure about soldering, using butt connectors is a simpler alternative. However, if you're experienced with soldering, it can provide a more secure connection. Regardless of the method you choose, ensure that the ground is reconnected properly to maintain the system's integrity.

Once the repair is complete, it's advisable to test the connections before sealing everything up with the final heat shrink. This step ensures that the repair is successful and that the system is functioning correctly.

If you discover additional issues during testing, such as another short or break, you'll need to address those as well. It's essential to tackle one repair at a time, starting from the closest point to the thermostat and working outward.

In conclusion, we hope this webinar has provided you with valuable insights into repairing in-floor heating systems. If you have any further questions or need assistance, please don't hesitate to reach out. Thank you for joining us today, and we look forward to seeing you at our next webinar on uncoupling membranes on December 14th. Don't forget to take advantage of our November promotion for free ground shipping on any order.

We appreciate your feedback and encourage you to contact us with any questions or concerns. Thank you for your time, and until next time, stay warm and be radiant.