How to Find and Repair a Break in Electric Floor Heating

Hello. Thank you for joining us in our October webinar. My name is Lynn, and I am a customer service representative at WarmlyYours. I'm joined today by Scott from WarmlyYours. Today, we're going to discuss how to find and repair a break in electric floor heating, a question that has become increasingly common. If you encounter any issues during your installation, knowing how to fix them is crucial, and we aim to address that today. If you have any questions during the presentation, please feel free to ask. At the bottom of the screen, there's a tab that says "Ask a Question." You can type your question there or in the sidebar chat, and we'll make sure to address them by the end of the presentation.

We'll be discussing some of our repair tools, including our splice kit repair and the solder method for repairs. Additionally, we want to inform you about our Smart Fix service, which provides assistance with fixing your issues. Scott, could you share some insights about the types of floor heating damage you commonly see and what typically happens?

To give everyone some background, I've visited hundreds of installations and repaired numerous systems across the U.S. Certain issues recur frequently, many of which stem from installation damage. The number one problem is that the installer often fails to read the installation manual. By thoroughly reviewing the manual and utilizing our website resources, including instructional videos, many of the common pitfalls can be avoided. A common misconception is that if there's a problem with the floor, the entire floor must be ripped up. I can't tell you how many times I've heard an electrician declare that a system needs to be removed and replaced after a simple test, sometimes conducted incorrectly. In my experience, I've seen only one floor that truly needed replacement, and that was due to extensive damage from improperly cleaned grout lines.

It's essential to differentiate between damage and installation error. The slide we have now illustrates two scenarios: one where damage occurred during installation and another where the installation was simply incorrect. A common sign of damage is a GFI message on the thermostat or a flashing red light. To delve deeper into how these repairs are conducted, we have extensive experience in troubleshooting, even for systems not sold by us. We utilize cutting-edge troubleshooting kits, which we'll describe later in the presentation.

When faced with issues like a non-functioning floor or a GFI problem, the first step is to use a simple digital ohm meter, which is readily available at any big box store for under $20. A frequent mistake during installation is nicking the wire with a sharp trowel while applying thinset. This is a very common error. I can personally attest to having cleared my trowel by hitting it on the floor, fortunately avoiding damage by hitting between the two wires. Mistakes like these happen, and it's crucial to be vigilant during installation.

Another overlooked aspect is the potential for damage before installation even begins. For instance, dropping a heavy bucket with sharp edges onto the wire can create a short by crushing it. Installers kneeling down in steel-toed boots may inadvertently kick the wire, causing shorts. While the wires are resilient and can withstand foot traffic, they are not impervious to sharp objects or heavy impacts. Installation manuals emphasize these risks, yet many installers neglect to read them thoroughly.

We also provide a circuit check, a device that tests for continuity. This tool is beneficial during installation; if a full bucket of thinset is dropped and the circuit tester beeps, it indicates that damage has occurred. Cleaning grout lines is another significant concern. I share this information because I receive hundreds of calls weekly from individuals asking for guidance on these very issues. Fortunately, our product is quite resilient, and if used correctly, it should not present significant problems.

Returning to the slide, the image at the top shows tools that allow us to heat specific sections of the product to identify where a failure has occurred. In the upper right corner, you can see that the damaged area aligns precisely with a grout line. This often happens when someone cleans grout lines without realizing there is electric heat underneath, leading to accidental damage. This reinforces the importance of reading the instruction manual, which specifically warns against such actions.

The slide also illustrates the difference between installation damage and incorrect installation. The upper right corner depicts installation damage, while the lower right corner shows a product that was not installed correctly. Although it heats well, there are significant cold spots due to improper spacing of the heating cables. Heat only travels about an inch and a half laterally, so if the wires are not spaced correctly, you can experience drastic temperature differences in the floor.

Now let's discuss our troubleshooting kit and its components. We offer these tools for rent, requiring a deposit due to their high cost. These tools should only be used by licensed electricians. The HIPOT tester, for example, is an insulation tester that sends high voltage down a line to check for leakage. If a GFI trips, it indicates that the thermostat detects leakage from the circuit to ground. We attach one probe to the ground and send voltage down one of the other wires to test for insulation integrity.

If we find that the insulation is compromised, we know we have a short. For instance, if a cable or mat is supposed to measure 100 ohms but tests at 50 ohms, it indicates a short circuit. The current is not flowing correctly, and we need to investigate further. We can use a thermal camera to identify where the short is located, as the damaged area will heat up more than the surrounding sections.

The cable fault finder is another valuable tool in our kit. It measures the length of the cable and can help pinpoint where the problem lies. If the reading indicates a fault 12 feet down the line, we know to focus our search in that area. Conversely, if the reading is 600 feet, we can redirect our search to the other end of the room. This tool is particularly effective when installation plans are followed, as it allows for more precise troubleshooting.

Moving on to the OMS test, this is performed on our newer twin conductor wire, which consists of two current-carrying wires and a ground. Electricians often only conduct part of the necessary tests, leading to incomplete assessments. To ensure a thorough evaluation, we need to test the circuit on the heating wires and between each wire and ground.

If a short is detected, we can use the Variac to apply voltage and identify the affected area. The multimeter, equipped with an amp clamp, allows us to monitor the amp draw while we heat the problematic section. If the amp draw increases, we know we're heating the right area.

Once we identify the location of the issue, we can proceed with repairs. It's crucial to be cautious during this process. For instance, if you need to break a tile to access the wire, you should score the grout line first to prevent further damage. Breaking the tile carefully allows you to access the wire without causing additional harm.

After removing the tile, you can use a thermal camera to locate the wire and mark its position. This step is essential for ensuring that you don't accidentally damage the wire further during repairs. Once you have access to the wire, you can proceed with the necessary repairs using the tools and techniques we've discussed.

There are two primary methods for making repairs: using crimp and solder connectors or soldering the wires directly. Each method has its advantages, and we provide detailed instructions for both. It's essential to ensure that the heat shrink tubing is applied correctly to protect the connection from moisture and damage.

After completing the repair, testing is crucial to ensure everything is functioning correctly. Before sealing up the repair, conduct the necessary tests to confirm that there are no shorts or issues with the connections.

Our Smart Fix service is a new offering that allows us to send a radiant heating expert to your project site for on-site repairs. If you're outside our service area, we also provide a Smart Guide service, which offers remote support via Zoom. This allows us to walk you through troubleshooting and repairs in real-time.

Now is the perfect time to ask any questions. We have a question from someone who submitted one in advance: how do I fix a system that was wired in series to one thermostat? Ideally, if you have two mats or cables in the floor, they should not be connected in series. Instead, each mat must run back to the thermostat separately, wired in parallel.

If one mat is tripping, you need to isolate the issue by testing each mat independently. Start by connecting one mat to the thermostat and running it to ensure it works. Then, test the second mat to identify any issues.

Another question we received is from Jackie, who has had her WarmlyYours system for six years. She mentioned that it doesn't warm up as expected, especially in colder weather. To address this, we need to determine whether the issue lies with the floor or the thermostat. Conducting ohm readings will help us identify the source of the problem. If the floor tests are good, we can then focus on the thermostat settings to ensure they are configured correctly.

If you have any more questions or want to learn more about luxury vinyl tile and floor heating, please join us for our next webinar on Thursday, November 12th. We will cover everything you need to know about luxury vinyl tile and floor heating.

Thank you for your participation today. Remember, if you encounter a problem with your floor heating system, you don't have to rip up the entire floor. We have the tools and knowledge to help you fix it. Until next time, stay warm and be radiant!