Chromalox CMi Installation guide

Installation & Operation Instructions

for Mineral Insulated Heating Cable

Embedded Snow Melting Applications

PJ964

161-562581-084

September 2012

CIT-1

Snow Sensor

APS-4C/3C

Snow/Ice

Controller

Junction

Box

SIT-6E

Pavement Sensor

JB-7

Junction Box

DRAFT 9/13/12

Mineral Insulated Heating Cable

Embedded Snow Melting Applications Installation and Operation Instructions

Inspection

s /PENPACKAGEANDVISUALLYCHECKFORBREAKSORDAMAGE

TOTHECABLE&ILECLAIMWITHCARRIERIFDAMAGEISFOUND

s .EVERENERGIZETHECABLEWHENITSCOILED4ESTONLYWHEN

ITSLAIDOUTSTRAIGHT

s !FTER REMOVING THE CABLE FROM THE CARTON CHECK THE

INSULATIONRESISTANCEOFTHEUNITFROMBUSSWIRESTOTHE

CABLEMETALSHEATH4ESTSHALLBECONDUCTEDAT6DC

BUTINABSENCEOFTHISTYPEOFEQUIPMENTA6DCTEST

WILLDETECTMOSTFAILURES

s 7HEN THE CABLE IS RECEIVEDCABLE SHOULD HAVE A MINI-

MUMINSULATIONRESISTANCEOF-1

General Design and Installation Notes:

s 3TANDARDSPACINGOF CABLESIS TYPICALLY v#ABLES CAN

BESPACEDUPTOv$ONOTINSTALLANYCABLECLOSERTHAN

vFROMTHEEDGEOFSLAB)FCABLESARESPACEDMORETHAN

vTHEAREABETWEENTHECABLERUNSMAYNOTMELTCOM-

PLETELY

s $ONOTBENDCABLETIGHTERTHANvINSIDEDIAMETER

s $ONOTOVERLAPCABLE

s $ESIGN SYSTEM SO THAT CABLES DO NOT CROSSEXPANSION

JOINTS )F CABLES MUST CROSS EXPANSION JOINTS SEE DIA-

GRAMINTHISDOCUMENT

s &ORSNOWMELTINGINPEDESTRIANAREASWATTDENSITYSHOULD

GENERALLYBEDESIGNEDATWATTSPERSQUAREFOOT

s &ORSNOWMELTINGINVEHICLEAREASUSETOWATTSPER

SQUAREFOOT

1.(EATERSSHOULDBEINSTALLEDINAUNIFORMPATTERNSIMI-

LARTOTHATSHOWNINFigure 1#ABLEDEPTHSHOULDBE

INCHESTOINCHESBELOWTHElNISHEDSURFACE

2.7HENINSTALLINGTHEHEATERSTOANEXISTINGSLABTHECA-

BLESSHOULDBESECUREDUSINGTHE330SPACERSTRIPAS

SHOWNINFigure 2ORBYATTACHINGTOAWIREMESH

3.4HEMINIMUMBENDRADIUSOFTHECABLEISTIMESTHEDI-

AMETER$ONOTBENDTHECABLETOOSHARPLY$ONOTMAKE

ABENDIN THECABLEWITHIN INCHESOFTHE BRAZEDHOT

COLDJOINTORTERMINATIONSLEEVE

4./NCETHEHEATERISINPLACEANDSECUREDPRIORTOCOVER-

INGCONDUCTAINSULATIONRESISTANCECHECKONTHEUNITS

AT6DC4HEINSULATIONRESISTANCEREADINGMUSTBE

NOLESSTHAN-1

Installing Cable in Concrete:

Figure 1

4YPICAL)NSTALLATION

Figure 2

4YPE3303PACER3TRIP



3HOULDITBENECESSARYTOPASSTHEHEATINGCABLETHROUGH

ANEXPANSIONJOINTITSHOULDBEDONEASSHOWNIN&IGURE!

OR"5SEMETHODSHOWNIN&IGURE!TOPASSUNDERJOINTS

!LLOWvOFCABLETOLOOPUNDERJOINT

5SEMETHODIN &IGURE"WHENIT ISNOTPOSSIBLE TOPASS

UNDERTHEJOINTORATWOPOURSLABISUSED

Expansion and Construction Joints:

Figure 3A

4YPICAL%XPANSION*OINT$ETAIL

Figure 3B

4YPICAL%XPANSION*OINT$ETAIL

(EATERSSHOULDBEINSTALLEDINAUNIFORMPATTERNANDHELD

IN POSITIONON THE BASE SLABUSING 330 SPACER STRIP OR

BYATTACHINGTOMESH!FTERTHECABLESAREINPLACEASMALL

AMOUNT OF ASPHALT SHOULD BE PUT OVER THE CABLES AND

TAMPED4HElNALTOPPINGCOURSESHOULDBEAMINIMUMOF

INCHESINTHICKNESSAFTERCOMPACTION

4HEMINIMUM BENDRADIUS OFTHE CABLEIS TIMESTHE DI-

AMETER $O NOTBEND THECABLE TOOSHARPLY$O NOTMAKE

ABENDINTHECABLEWITHININCHESOFTHEBRAZEDHOTCOLD

JOINTORTERMINATIONSLEEVE

/NCE THE HEATER IS IN PLACE AND SECURED PRIOR TO COVER-

ING CONDUCT A INSULATION RESISTANCE CHECK ON THE UNITS

AT6DC4HEINSULATIONRESISTANCEREADINGMUSTBENO

LESSTHAN-1

Special Surface Treatments

7HENSLABSURFACESARETOBETOPPEDWITHDECORATIVETILE

BRICKMARBLEGRANITEETCITISRECOMMENDEDTHATTHECABLE

BEATTACHEDTOTHEREINFORCING)FTHISISNOTPOSSIBLETHEN

THECABLESHOULDBEINSTALLEDINTHEGROUTBENEATHTHETILEAS

SHOWNINFigure 4/NCECABLEISCORRECTLYPOSITIONEDTHE

BASESLABSURFACEMUSTBEPREPAREDPROPERLYTORECEIVETHE

TOPPING#AREMUSTBETAKENWHENAPPLYINGTHEDECORATIVE

TOPPINGNOTTODAMAGETHECABLE

Heater Unit Termination:

%ACHHEATERUNITISTERMINATEDWITHABRAZEDSEALANDPRES-

SURElTTINGFORATTACHINGCABLEINTOCONDUITHUB3EEFigure

5FORDETAILS

Installing Cable in Asphalt:

Figure 4

4YPICAL$ETAIL7ITH#ABLE)N'ROUT

Figure 5

4YPICAL$ETAIL7ITH#ABLE)N'ROUT



Slab Temperature Sensor:

Control, Monitoring, and Power Distribution

4OPREVENTCABLEFROMBEINGENERGIZEDDURINGTIMESITSNOTNEED-

EDANDFORENERGYEFlCIENCYASEPARATESLABSENSINGTHERMOSTAT

OR INTEGRAL TEMPERATURE SENSOR SHOULD BE USED 4HESE SENSORS

SHOULDBEUSEDINCONJUNCTION WITHTHEAUTOMATICSNOWMELTING

CONTROLPANELS 4HE TEMPERATURE SENSOR SHOULD BE INSTALLED BE-

TWEENTWORUNSOFHEATINGCABLEANDSHOULDBEINSTALLEDINMETAL

CONDUIT$ONOTALLOWTHECONDUITTOTOUCHTHEHEATINGCABLEAND

CAPTHEMETALCONDUITSOTHATITISWATERTIGHT4HECONDUITSHOULD

BELONGENOUGHTOEXTENDTOTHEMIDDLEOFTHEAREABEINGHEATED

#HROMALOXSNOWMELTSYSTEMSSHOULDBECONTROLLEDINONEOFTHE

FOLLOWINGTHREEWAYS

-ANUAL/N/FF#ONTROL

s 4HEPOWERORCIRCUITBREAKERSAREMANUALLYOPERATED

3LAB3ENSING4HERMOSTAT

s 4HESYSTEMWILLENERGIZEWHENTHESLABTEMPERATUREDROPSBE-

LOWTHEFREEZING4HESYSTEMWILLCOMEONEVENWHENMOISTURE

ISNOT PRESENT 4HEREFORETHIS IS NOTTHE MOST ENERGYEFlCIENT

METHODOFCONTROL

!UTOMATIC3NOW#ONTROLLER

s 4HE METHOD SHOWN BELOW IS THE MOST ENERGYEFlCIENT METH-

OD 4HE CABLE WILL BE AUTOMATICALLY ENERGIZED WHEN MOISTURE

ISPRESENTANDTHETEMPERATUREISBELOWFREEZING4HESYSTEM

WILLALSOBEDEENERGIZEDAUTOMATICALLYONCETHESLABREACHES

THE TEMPERATURE SET POINT ! BUILTIN TIMER KEEPS THE SYSTEM

ENERGIZEDFORASETTIMETOALLOWSLABTODRYCOMPLETELYONCETHE

MOISTUREISNOLONGERPRESENT

4EMPERATURE/NLY 4EMPERATUREAND-OISTURE



"RANCHCIRCUITWIRING-534COMPLYWITHLOCALANDNATIONAL

ELECTRIC CODES (EATER UNIT COLD SECTIONS ARE AVAILABLE IN

ANYLENGTH TO REACHREMOTEJUNCTION BOX LOCATIONS)F ANY

PORTIONOFTHECOLDSECTIONISTOBEBURIEDITMUSTBEBURIED

ATAMINIMUMDEPTHOFINCHES

*UNCTIONBOXESAREPREFERABLYLOCATEDINDOORASINFigure

6/UTDOORWALLMOUNTEDJUNCTIONBOXESMUSTBEOFWEATH-

ERPROOFCONSTRUCTIONANDLOCATEDATLEASTTHREEFEETABOVE

GRADE AS IN Figure 7 /UTDOOR ONGRADE mUSH MOUNTED

JUNCTION BOXES AS IN Figure 8 MUST BE PROVIDED WITH A

DRAIN AND GASKETED COVER "OXES INSTALLED IN THE SLAB

SHOULDBE AVOIDEDDUE TO POSSIBILITYOF THEACCUMULATION

OFCONDENSATE

s #HECK TO ENSURE INCOMING ELECTRICAL SUPPLY IS CORRECT

VOLTAGETOBEHOOKEDUPTOHEATINGCABLE

s 5SE#IRCUIT"REAKERSWITHM!GROUNDFAULTPROTECTION

ONALLHEATINGCABLECIRCUITS

s 2EFERTOWIRINGDIAGRAMSOFSNOWMELTCONTROLSFORWIRING

CONlGURATIONS

Wiring:

Figure 6

4YPICAL)NDOOR*UNCTION"OX

Figure 7

4YPICAL/UTDOOR!BOVE'RADE*UNCTION"OX$ETAIL

Figure 8

4YPICAL"URIED*UNCTION"OX



1. )F INSTALLING CABLE ON STAIRS WITH AN ATTACHED LANDING

WHEREANEXPANSIONJOINTSEPARATESTHESTAIRSANDLAND-

INGDONOTCROSSTHEEXPANSIONJOINTWITHTHECABLE!

SEPARATECABLEWILLBENEEDEDFORTHELANDING

2. )NSTALL JUNCTION BOXES 7HEN USING SINGLE CONDUCTOR

CABLESTHEJUNCTIONBOXWILLNEEDTOBELOCATEDCLOSETO

WHERETHECABLESTARTSANDENDS

3. 0LAN THE CABLE LAYOUT ON THE STEPS -ARK LOCATIONS

WHERERAILPOSTSWILLBEINSTALLEDONTHESTAIRSANDKEEP

THEHEATINGCABLEAWAYFROMTHESEAREASTOAVOIDDAM-

AGETOTHECABLE

4. ,AYOUTHEATINGCABLEASSHOWNBELOWANDFASTENCABLE

TOTHEREINFORCEMENT&ORSTEPSWITHADEPTHOFTO

INCHESTHREERUNSOFHEATINGCABLEARENEEDEDWITH

THElRSTRUNBEINGTOINCHESFROMFRONTOFSTEPAND

THEREMAININGTWORUNSSPACEDEQUALLYAPART&ORSTEPS

WITHADEPTHOFLESSTHENINCHESTWORUNSOFCABLE

ARENEEDEDWITHlRSTRUNTOINCHESFROMTHEFRONTOF

STEPANDTHESECONDRUNSPACEDINCHESFROMTHElRST

RUN OF CABLE 3TAY AT LEAST  INCHES FROM OUTER WALLS

EDGESANDRAILPOSTANCHORPOINTS

5. )NSTALLHOTCOLDJOINTSSOTHATTHEYAREATLEASTINCHES

FROMTHEEDGEOFTHESLABSOTOENSUREITWILLBECOM-

PLETELYEMBEDDED

6. )NSTALLTHECONDUITFORTHESLABTEMPERATURESENSOR

7. 6ISUALLYINSPECTCABLESCOLDLEADSANDJUNCTIONBOXES

TOINSUREPROPERINSTALLATION

8. "EFORECONCRETEISPOUREDCHECKINSULATIONRESISTANCE

OFTHECABLESAT6DC-INIMUMACCEPTABLEREAD-

INGIS-1

9. 0OURATOINCHTHICKNESSOFCONCRETEOVERTHEHEAT-

ING CABLES AND CONTINUOUSLY CHECK THE INSULATION RE-

SISTANCE WHILECONCRETE ISBEING POURED TOENSURE NO

DAMAGEISBEINGDONETOCABLES-INIMUMACCEPTABLE

READINGIS-1AT6DC

10.#ONNECTCOLDLEADSTOTHEJUNCTIONBOX

11.4HESLABTEMPERATURESENSORCANBEINSTALLEDAFTERIN-

STALLATIONOFCONCRETEISCOMPLETE

Installing Cable in Stairs (Single Pour):

Figure 9

4YPICAL3INGLE0OUR$ETAIL

1. )F INSTALLING CABLE ON STAIRS WITH AN ATTACHED LANDING

WHEREANEXPANSIONJOINTSEPARATESTHESTAIRSANDLAND-

INGDONOTCROSSTHEEXPANSIONJOINTWITHTHECABLE!

SEPARATECABLEWILLBENEEDEDFORTHELANDING

2. )NSTALL JUNCTION BOXES 7HEN USING SINGLE CONDUCTOR

CABLESTHEJUNCTIONBOXWILLNEEDTOBELOCATEDCLOSETO

WHERETHECABLESTARTSANDENDS

3. 0LAN THE CABLE LAYOUT ON THE STEPS -ARK LOCATIONS

WHERERAILPOSTSWILLBEINSTALLEDONTHESTAIRSANDKEEP

THEHEATINGCABLEAWAYFROMTHESEAREASTOAVOIDDAM-

AGETOTHECABLE

4. )NSTALLPREPUNCHEDSTRAPPINGUSINGAPPROPRIATEFASTEN-

INGMETHODATTOFEETINTERVALSWITHADDITIONALRUNS

TOSECURECABLELOOPSSECURELY

5. ,AYOUTHEATINGCABLEASSHOWNBELOWANDFASTENCABLE

TOTHEPREPUNCHEDSTRAPPING&ORSTEPSWITHADEPTHOF

TOINCHESTHREERUNSOFHEATINGCABLEARENEED-

EDWITH THElRST RUNBEING TO INCHESFROMFRONTOF

STEPANDTHEREMAININGTWORUNSSPACEDEQUALLYAPART

&ORSTEPSWITHADEPTHOFLESSTHENINCHESTWORUNS

OFCABLEARENEEDEDWITHlRSTRUNTOINCHESFROMTHE

FRONTOFSTEPANDTHESECONDRUNSPACEDINCHESFROM

THElRSTRUNOFCABLE3TAYATLEASTINCHESFROMOUTER

WALLSEDGESANDRAILPOSTANCHORPOINTS

6. )NSTALLHOTCOLDJOINTSSOTHATTHEYAREATLEASTINCHES

FROMTHEEDGEOFTHESLABSOTOENSUREITWILLBECOM-

PLETELYEMBEDDED

7. )NSTALLTHECONDUITFORTHESLABTEMPERATURESENSOR

8. 6ISUALLYINSPECTCABLESCOLDLEADSANDJUNCTIONBOXES

TOINSUREPROPERINSTALLATION

9. "EFORECONCRETEISPOUREDCHECKINSULATIONRESISTANCE

OFTHECABLESAT6DC-INIMUMACCEPTABLEREAD-

INGIS-1

10.0OURATOINCHTHICKNESSOFCONCRETEOVERTHEHEAT-

ING CABLES AND CONTINUOUSLY CHECK THE INSULATION RE-

SISTANCE WHILECONCRETE ISBEING POURED TOENSURE NO

DAMAGEISBEINGDONETOCABLES-INIMUMACCEPTABLE

READINGIS-1AT6DC

11.#ONNECTCOLDLEADSTOTHEJUNCTIONBOX

12.4HESLABTEMPERATURESENSORCANBEINSTALLEDAFTERIN-

STALLATIONOFCONCRETEISCOMPLETE

Installing Cable in Stairs (Two Pour or existing):

Figure 10

4YPICAL4WO0OUR$ETAIL



1347 HEIL QUAKER BLVD., LAVERGNE, TN 37086

Phone: (615) 793-3900 www.chromalox.com

Limited Warranty:

Please refer to the Chromalox limited warranty applicable to this product at

http://www.chromalox.com/customer-service/policies/termsofsale.aspx.

¥#HROMALOX)NC

Visual Inspection

s )NSPECT *UNCTIONBOXES CABLE TERMINATIONS AND CON-

NECTIONSTOTHECABLEFORPHYSICALDAMAGE

s )NSPECTCOLDLEADSIFTHEYEXITTHESLABFORPHYSICALDAM-

AGE

s )NSURETHATMOISTUREISNOTPRESENTINTHEJUNCTIONBOX-

ES

s #HECKTHATELECTRICALCONNECTIONSARETIGHTANDTHATTHE

.04CONNECTORSARETIGHTANDPROPERLYGROUNDED

De-energize circuit(s) before performing insulation re-

sistance check

Insulation Resistance Check

4HISTESTSHOULDBEPERFORMEDTIMESTHROUGHOUTTHEIN-

STALLATIONPROCESS

s 7HENRECEIVED-IN-1

s !FTER)NSTALL-IN-1

s #ONTINUOUSLYWHILEDURINGINSTALLATIONOFCONCRETEAS-

PHALTECT-IN-1

s 0RIORTOSTARTUPCOMMISSIONING-IN-1

4HISTESTSHOULDALSOBEPERFORMEDASPARTOFAREGULARSYS-

TEMINSPECTIONANDAFTERANYMAINTENANCEORREPAIRWORK

COMMISSIONING AND PREVENTATIVE MAINTENANCE

System Tests

Chromalox CMi Installation guide

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