You will need to use a digital multi-meter to test the resistance readings of your heating system before, during and after installation. This tool will ensure that there are no nicks, tears or breaks in the wire during installation. Please see the below instructions on how to use a digital multi-meter:
1.Ensure that the thermostat and heater are disconnected from the power source before proceeding. 2.Turn the range selector on the meter to the 200 Ω position. 3.Plug the red test lead into the VΩmA (center) jack. 4.Plug the black test lead into the Com (bottom) jack. 5.Push the “Off/On” switch on the multi-meter to the “On” position. 6.Short the test leads together; the meter should read 0 ohms. 7.Touch the red probe lead to the white/red/yellow wire from the floor heater. 8.Touch the black probe lead to the black wire from the floor heater. 9.Read and record measurement on display. 10.Compare to resistance reading expected (this will be available on the box that the wire or mat comes in). The reading needs to be +/- 10% of what is expected. 11.Touch the black probe lead to the black wire from the floor heater. 12.Touch the red probe lead to the ground wire from the floor heater. 13.Read and record measurement. 14.Touch the black probe lead to the ground wire from the floor heater. 15.Touch the red probe lead to the red/white/yellow wire from the floor heater. 16.Read and record measurement. 17.If all 3 resistance readings are within range, proceed to the next step of installation. 18.If the readings are more than +/- 10% of the expected reading, contact Warmup Technical Support before proceeding.
1.2 Repairing Your Heating System Using a TDR Meter
Sometimes the worst case scenario happens with your heating system during installation: a complete break, nick or tear in your wire has been created. After checking with a Warmup representative to ensure this diagnosis (you must have a licensed electrician check your resistance readings: line to line and both ground readings and then call Warmup with the results so we can confirm there is some sort of break in your wire), you are able to rent a TDR Meter. This Meter (Time Domain Reflectometer) will send out currents through your heating system to locate the break. Once that break has been located, your licensed electrician will be able to fix it with the supplied repair kits that come with the rented meter. Below are step by step instructions on how to use the TDR Meter:
1.The meter is already set to the specifications you need to find the fault so all you need to do is press the power button to activate. Connect the included alligator clips to the meter following the color coding indicated (black to black, red to red). 2.Cut all electricity going to your thermostat and disconnect the heating system from the thermostat. 3.Press power on your TDR meter to begin. 4.First attach one clip to one of the lead wires of the heating system and connect the other clip to the ground wire (metal ground sheath of the heating cable). Press F1 (for length) and wait for the reading. Compare this number to the manufactured length of the wire indicated in the cable installation manual. You will now see how many feet it is to the break. Repeat this process but now get a reading from other lead wire. 5.IF THE READINGS ARE THE SAME: If the readings on both sides are the same and within 10% of the total length of the wire (see product specs or manual), you should be in good shape. It can however mean that your break is at the far end of the wire. The most common scenario is a damaged end splice (the tail of the wire). If your readings are the same but significantly shorter than the factory length of the wire, it could indicate that you have a complete break. For example, on a 25sqft mat (NADWM-120-350), the cable is 100ft and the mat is 15ft. If your TDR readings are well short of 100ft, then you may have a clean break in the wire.
Confirm your readings with a multi-meter:
Black to White: see factory settings. If you have no readings here, it might indicate or confirm you have a break. Before jumping to conclusions, double check the batteries on your reader and re-do the measure. Ensure to use a digital multi-meter (digital screen), not an analog one (with a needle indicator). You also must complete 2 readings for ground—black to ground and white/red/yellow to ground.
6.IF THE READINGS ARE DIFFERENT: If the readings on the black and white side are different, write down your readings. What happens here is that the wire is partially damaged, and the signal on one side hits the damage and the reading on the other side goes all the way to the end of the cable, and then hits the damage on the return. In the example of the 25sqft mat above, if a partial damage is found 30ft away on the white side of the cable, then one reading will read 30ft and the other will read 170ft. That is 100ft to the end of the black side (no damage) and 70ft backwards returning on the white side of the cable. 7.Once you have written down your readings and made a written map of the cable or mat layout and the possible location is to carefully lift the tile over the suspected area. Be careful with grinders if you use them, and favor smaller tools and a slower process rather than the industrial-grade chisel and hammer. A smaller chisel will allow you to reduce further damage to wire. 8.If things go well, you will find a break. You are looking either at a black/dark spot in the thin set where the cable burned out, or, after uncovering and loosening the cable, a crushed spot on the cable. You can typically spot these with bare hands by running your fingers on the break. More often than not, this is not the spot where the break lies. If the break is not here, cut the wire on purpose and carefully clean the ground and conductors on both sides. You will have one side heading to the thermostat and one side aiming to the tail of the mat. Let’s call them upstream (thermostat) and downstream (tail-end). When cleaning up the wires and exposing the copper, we recommend using a utility knife with a fresh blade. The wires are so small that most wire strippers will simply break the cable.
9.ISOLATE THE SIDE WITH THE BREAK: To identify whether the break is upstream or downstream from your cut, use your ohm-meter. Twist the black and white together at the thermostat with a wire nut (do not connect the ground wire). Check the ohm’s normally from your cut towards the thermostat. You should have a reading (a fraction of the factory reading since you’re not measuring the entire cable), and an open circuit to ground. If that’s not the case, your break is on that side and you should repeat the TDR steps above to identify how far from your cut the break now is. If your original drawing and approximation was good, you should be pretty close and read a small number of feet. If your circuit is fine, turn to the other side of your cut and use the multi-meter to check readings towards the tail of the mat (downstream). If the ohms do not show a complete circuit, repeat the TDR instructions above to get nearer to the break. 10.ONCE THE BREAK IS FOUND: When you have found the break, we suggest you first simply twist all the wires back together in order to establish a complete circuit from the thermostat. Measure the ohms to confirm you have restored the original or close to original readings. There is no polarity in the cable, which means that you can interchange the two conductors at any point. While the cables are color-coded at the thermostat level, they are all the same under the floor.
Follow the instructions in the Warmup repair kit to complete your connections.
1.3 Repairing a Break In The Wire
You will need to request a Warmup Repair Kit from your reseller and then follow the included instructions. NOTE: The junction wire that is included in the repair kit that serves as a bridge between the heated wire does not heat up.href="http://www.warmup.com/media/pdf/US-loose-wire-heater-repair-instructions-web.pdf#zoom=100">Click Here to view them now.