Tips for Troubleshooting Electric Floor Heating System

My name is Lynn, and I am a customer service representative here at WarmlyYours. I am joined by one of our fabulous technical support team members, Scott. Today, we will be discussing some tips for troubleshooting electric floor heating systems. If you have any questions, please don’t hesitate to ask in the chat. You can definitely type them out, and if we don’t see them right away, we will address them by the end of the presentation.

As mentioned, we will cover troubleshooting steps, starting with testing the system to ensure it is functioning properly. If any issues arise, we will go over troubleshooting steps as well as the actual procedures for repairing a floor heating cable. Scott will guide us through the technical aspects of this process.

To provide a brief overview, electric floor heating systems offer comfortable temperatures from floor to ceiling, eliminating the hot and cold spots often associated with forced air systems. With electric floor heating, you can enjoy a consistent and pleasant warmth without the need for maintenance, unlike hydronic systems that require boilers and pumps. Once our electric floor heating systems are installed, they require no further maintenance and are ready for use. Ideal for remodeling projects and new builds, our systems can be installed beneath new flooring. If you have upcoming projects, let us know, and we can assist you in selecting the right flooring.

Our electric floor heating systems are also easy to control. All of our thermostats come equipped with a floor sensor, allowing you to regulate the temperature of the floor to the exact degree. Additionally, our systems are wet location listed, making them suitable for installation in showers, shower benches, and wet rooms. Essentially, we have a product that can accommodate nearly any space where you wish to install floor heating.

Regarding floor heating controls, each thermostat features a sensor, and we offer various models to suit different needs. From Wi-Fi touchscreen models that can be controlled via smartphone to simple non-programmable on-and-off thermostats, we have options to customize your system. If you need assistance selecting the right thermostat or setting it up, please feel free to reach out.

Now, I’d like to bring in Scott to share his technical expertise on preparing the floor heating system to minimize troubleshooting issues. Scott, can you explain the importance of not cutting the heating wire?

Absolutely, Lynn. The main point to remember is that you can never cut the heating wire. We receive this question frequently: "I have too much cable; can I use part of it in one room and another part in a different room?" The answer is no; you cannot cut or shorten the mat in any way. This is the most critical aspect to understand.

It is essential to test the system the day you receive it using a digital ohm meter. You cannot perform this job without a digital ohm meter, so it’s advisable to acquire one. We will discuss what to look for and what to avoid when using it. Testing the system upon arrival is crucial in case any damage occurred during shipping, allowing us to arrange a replacement without delaying your installation.

During the installation day, you should test the system before, during, and after installation to ensure everything is functioning correctly. This testing serves as a record of a successful installation.

Scott, could you elaborate on circuit checks and their significance?

Certainly! A circuit check is a device that monitors your system while you are busy with installation tasks. When you are laying tile or working on the floor, you cannot keep your eyes on the meter. The circuit check tracks the condition of the wire. Inside the wire, there are three cables: two that carry current and heat up, and one that serves as a ground. The circuit check ensures that there is no connection between the ground and either of the current-carrying wires. It also verifies that you have a circuit capable of heating; if the circuit is cut and goes open, you will not receive any heat.

Now, regarding the use of an ohmmeter, what specific readings should we be looking for?

When using an ohmmeter, you want to select the 200 range on the left side of the meter. The center meter is expensive and often harder to use due to its self-ranging feature. You should avoid meters that only have an upside-down horseshoe symbol for ohms and a range button, as they can be cumbersome to operate. The analog meter on the right should also be avoided, as it will not provide usable information.

The ideal meter allows you to switch between the 200 and 20K ranges easily, which is necessary for testing our products. Many customers have called us about issues with meters that do not provide readings on the 20K scale without repeatedly pressing the range button.

Now, could you walk us through the process of testing with the ohmmeter?

Certainly! When testing, you will see two current-carrying wires, typically black and yellow or black and red. You want to measure ohms between these two wires, and you should not get any readings from either wire to ground, as that would indicate a short. The ohm reading between the black and red wires should be 240, while between yellow and black, it should be 120.

It’s important to remember to conduct all three readings: yellow to ground, red to ground, and black to ground. You should aim for zero or OL (open loop) readings between the wires and ground, while expecting an ohm reading within 10 to 15% across the heating wires.

We also receive inquiries about testing our old single conductor cables. Can you explain how to test those?

Certainly! The single conductor cable resembles a coax cable, with a center copper wire surrounded by insulation and an outer braid. You will need to test both ends of the cable. Measure ohms from center core to center core and from outer braid to outer braid. You should not get any readings from the center core to the outer braid or from the center core to ground.

Now, let’s discuss the Megohm meter. What is its purpose?

The Megohm meter is a device that sends a high voltage down the wire, typically 500 or 1000 volts, compared to the 9 volts from standard meters. It tests the insulation between the three wires to ensure they do not touch each other or ground. A small nick in the wire may not show up with a digital ohm meter, but it could cause a GFI problem. The Megohm meter can detect these issues because it uses higher voltage, which can jump across small gaps in insulation.

After testing, it’s important to let the meter dissipate its charge to avoid electric shock.

Moving on to thermostat testing, we recommend performing this monthly, especially before winter. Can you outline the testing process?

When testing the thermostat, press the test button. It should display a ground fault message, indicating that the GFI sensing circuit is functioning correctly. If you receive this message, it is working as intended. Pressing the button will clear the message.

If you encounter system damage, the first step is to identify the issue. A GFI message indicates leakage, meaning power is escaping from one of the wires to ground. The red spot in the upper right corner of the image shows where the ground is touching a power-carrying lead, creating a short circuit.

This short can develop over time due to the expansion and contraction of the wire, often caused by sharp tools during installation. It’s crucial to inform every trade person involved in the project about the presence of electric heating to prevent accidental damage.

Common installation problems include damage from plumbers or trim installers who may inadvertently hit the wire. If part of the floor is hot while another part is cold, it may indicate improper installation.

The heat only travels about an inch and a half laterally from the wire, so if the heating cable is not laid out correctly, you will experience cold spots. We recommend using a SmartPlan to prevent these issues, as it provides a detailed layout for installation.

Scott, can you explain the troubleshooting kit we offer?

We rent out troubleshooting kits equipped with expensive tools to help identify problems without needing to rip up the entire floor. The high pot tester sends voltage down the wire to locate shorts, while the Variac transformer allows you to gradually increase voltage to see where the heat is generated.

The thermal camera helps visualize hot and cold spots, and the digital multimeter is used for ohm testing. The cable fault finder can indicate the distance to a problem, but it is most effective when used with a layout plan.

It’s important to note that testing should be performed by a licensed electrician due to the high voltages involved.

When it comes to locating the problem, the Hypot can shoot up to 2500 volts down the line to create a short and identify the location of the cut wire. This process can create a hot spot that can be detected with a thermal camera, allowing for targeted repairs rather than a complete floor replacement.

Once the damaged area is identified, only a small section of flooring may need to be removed for repair. It’s essential to avoid damaging surrounding tiles during this process.

Key takeaways for planning your project include understanding that heat will only be present where the cable is installed. Be sure to inform us of any plumbing, columns, or floor vents when creating your SmartPlan.

The image illustrates proper cable spacing and temperature consistency across the floor. Areas without insulation, such as concrete slabs, will not heat as effectively. Using Cerazorb over concrete is crucial for optimal heating performance.

If you experience heating issues, always start by testing for ohms to identify the problem area. If a section of the floor does not heat, disconnect it from the power module and test for ohms to determine if the issue lies within that specific roll.

Regarding older thermostat models, common issues include transformer failures and mechanical relay malfunctions. If the thermostat is receiving power but not functioning, it likely needs to be replaced.

For customers with older thermostats, we offer a 50% discount on replacements if we can locate your order in our system.

Lastly, if a sensor was forgotten during installation, it can be added later by carefully routing it into the grout line between heating wires.

Repairing a floor heating cable involves splicing the wires together, using waterproof heat shrink tubing to ensure a secure connection. Detailed instructions and videos are available for those needing guidance through this process.

If there are any questions from our participants today, please feel free to ask.

Our next webinar will be on Thursday, September 14th, at 1:00 PM, focusing on snow melting for asphalt driveways. We will cover installation steps and more.

We also offer daily training sessions on Zoom, hosted by our technical support team.

For August, we have a promotion offering 15% off all snow melting systems.

After this session, we will send an email requesting feedback on your experience today. We appreciate your comments and suggestions for future webinars.

If you have any questions or need assistance, please reach out via phone, email, or our website, where you can find a wealth of information.

Thank you, Scott, for joining me today and sharing your expertise. Until next time, stay warm and be radiant!