Radiant Surfaces General InstructionsThe instructions in this manual must be followed when preparing and installing the Radiant Surfaces - Floor-Warming System. This manual and the installation layout should be made available to all installers and theelectrician working on the job. Both should then be turned over to the homeowner after the installation iscomplete. FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL MAY VOID THEHOMEOWNER’S WARRANTY ON THE FLOOR-WARMING MAT. THE OJ THERMOSTAT ISWARRANTED FOR 3 YEARS FROM DATE OF PURCHASE.

Temperature and Time ControlFor optimal control of the Radiant Surfaces - Floor Warming System, use a Floor-Sensing ProgrammableThermostat such as the OJ UCG-4991 120/240 Volt Automatic Control.The temperature sensing is accomplished by placing a sensor in the heated area under the flooring surface.This versatile unit can be programmed to operate at varying temperatures for different time periods on a dailybasis. Another beneficial feature of the OJ Programmable Thermostat is the internal GFCI.

Radiant Surfaces Floor-warming systems can also be regulated by a manual floor-sensing thermostat. Pleasecontact the Radiant Surfaces Sales Department at 888-658-0988 for further details.

Control installation guidelines are listed on pages 3 & 4 of this manual.

MaintenanceThe Radiant Surfaces floor-warming system has no moving parts and is virtually maintenance-free.The internal OJ GFCI (Ground Fault Circuit Interrupt), should be tested monthly as described in themanufacturer’s pamphlet to insure its continued safe operation. If an external GFCI is utilized instead, itshould also be tested monthly.

Sub-Floors and Floor CoveringsRadiant Surfaces mats may be installed over any well-insulated sub-floor (i.e. plywood, concrete, or underlayment material) prepared in accordance with all TCNA guidelines and rated to withstand 180 degrees Fahrenheit.

SPECIAL CONSIDERATION:Radiant Surfaces mats will be most effective and efficient if installed over well-insulated areas. Insulationwill minimize heat loss into the sub-floor (i.e. concrete slab), allowing the heat to transfer to the surfacemore quickly. We recommend Schluter Systems Ditra underlayment over concrete slabs as a thermalbreak with Radiant Surfaces mat on top of Ditra. This allows the heat to warm the tile isolating theconcrete floor.

Radiant Surfaces will be most effective if installed under rigid floors that are naturally good conductors of heatsuch as ceramic tile, marble, and other stone floorings. There are limitations in applications that utilizedifferent floor coverings. Please consult with your Radiant Surfaces Marketing Representative for details onheating parquet or engineered wood floors.

523 San Ramon Valley Blvd, Danville, CA 94526Phone: 925-831-1616 Fax: 925-838-0329

1

Planning the Installation

Before laying the Radiant Surfaces - floor/counter warming system, review the installation layout andverify that all dimensions match the field dimensions. The installation plan should include the following:

1. Placement, direction, and dimensions of the Radiant Surfaces heating mat. Snapping chalk lineswill aid the placement of mats according to your layout drawing.

2. The starting and ending points of each mat3. The location of the thermostat or other suitable control4. The location of the floor sensor

IMPORTANT INSTALLATION CONSIDERATIONS

2

DON’T1. DON’T shorten the heating mat.2. DON’T cut the heating wire.3. DON’T drop or bang any tools (i.e. trowel) on

or hit the heating wires with any sharp objects.4. DON’T install any fasteners such as nails,

screws, etc. through any area covered by theRadiant Surfaces mat.

5. DON’T install Radiant Surfaces undercabinets,built-in appliances, etc. to avoidexcessive heat from building up in those areas.

6. DON’T install mats over expansion joints.7. DON’T install Radiant Surfaces in walls.8. DON’T install Radiant Surfaces in showers

unless under a vapor proof membrane on top.9. DON’T overlap mats or allow any wires to

cross or touch each other.10. DON’T crimp the heating wire while

customizing the mat.11. DON’T place area or throw rugs thicker that

½” over the heated area to avoid excessivebuild-up of heat in these areas.

12. DON’T attempt to repair the heating wirewithout the proper instructions and repair kit(obtained from your distributor).

13. DON’T forget to install the floor-sensor if youare installing a thermostat.

14. DON’T install Radiant Surfaces in glues otherthan cement-based tile-setting mortars.

DO1. Clean the floor of all debris before placing the

mat on the floor.2. Make sure there are no protruding objects

(nails, staples, etc.) on the sub-floor that coulddamage the heating element.

3. Walk over the unprotected mat with rubber-soled shoes.

4. Measure and record mat resistance as perinstructions.

5. Use mats that have the same heat output. ALLmats should be ALL 12 watts/sqft.

6. Make sure all components of the system arerated for the same Voltage (120V OR 240V).

7. Have all electrical work completed by aprofessional electrician in accordance with alllocal and national codes.

8. Connect Radiant Surfaces Mats to aDedicated Circuit.

9. Call our Technical Support Hotline at1-925-831-1616 if you need answersto installation questions, need help solving aproblem, or believe that the mat got damagedduring installation.

Radiant Surfaces Electrical Rough-In forOJ Programmable T-Stat

3

Conduit to PowerSource

A Dedicated Circuit is recommended forALL installations. A Separate Power Modulewill be required if theheating current exceeds15 Amps.

1/2” Conduit forSensor Wire

(Must be keptSeparate from

Cold Lead Wires)

3/4”Conduit

forCold Leads

Sensor is in theThermostatBox - It mustbe installed

2 1/8” X 4”Deep Junction Box

OR4” X 4”

Deep Junction Boxwith Adjustable

Mud Plate forThermostat withInternal GFCI

Electrical Preparation - OJ Programmable T-StatAll Electrical Connections for the Radiant Surfaces Warming System and Controls should be done by aProfessional Electrician in accordance with all Local and National Electrical Codes.

Rough-In Electrical: Requires a Dedicated Circuit1. A deep, 2 1/8” X 4” single-gang junction box (OR a “roomier” 4” X 4” double-gang box with a

mud plate) should be provided by the electrician for the thermostat connections. (See Rough-InElectrical Preparation Diagram on page 3.)

2. Two conduits should be run down from the junction box.a. The first conduit, intended for the cold leads from the mat(s), should be ¾” and must be

run from the junction box down to floor level. A plastic bushing should be used where thecold leads enter the conduit to protect the wires.

b. The second conduit, intended for the OJ floor-sensor, can be a ½”conduit. This ½”conduit should be run from the junction box down to floor level. THE SENSOR WIRESHOULD NEVER BE PLACED IN THE SAME CONDUIT AS THE COLD LEADS.

OJ Sensor PlacementThe OJ floor sensor should be installed after the heating mat has been secured to the sub-floor,but BEFORE it is covered with any mortar. Make sure to place the sensor between the heating elementwires without crossing or touching any of the element wires

Extending The LeadsThe cold leads extend approximately 10 feet from the mat. Since the cold lead(s) cannot be spliced in thefloor, the mat should be laid in a pattern that allows the cold lead(s) to run directly to the junction boxwithout crossing or touching any element wires. However, if the cold lead(s) need to be extended, anadditional accessible junction box should be set just above floor level. The Gage of the extension wire(s)used should be determined by the electrician to accommodate the amperage of the mat(s) being installed.REMEMBER! Inaccessible extensions or splices are not permitted.

Multiple Mat InstallationsIf the project requires more than ONE Radiant Surfaces mat to be connected to the same control, the coldleads from the mats should be connected IN PARALLEL ( NOT IN SERIES) through an additionaljunction box and extended through the conduit to the thermostat junction box. The Gage of the extensionwires used should be determined by the electrician to accommodate the amperage of the mats being installed.(See Section below labeled “Use of a Power Module with GFCI” for further details.)

Use of a Power Module (for Multiple Mat Installations in Large Areas)

IMPORTANT!

To control large areas with one OJ Thermostat, a power module will be needed. OJ USG-4000 Power Moduleis connected by wire to the OJ Thermostat UCG-4991 which controls the time & temperature for the entirefloor. Each unit is 15 AMPS & requires a dedicated 15 AMP circuit.

Please contact Radiant Surfaces for a custom layout using the OJ Thermostat & Power Module

The installation layout may be designed to split the area in two different zones. Separate OJ Thermostats willbe used in each zone, each thermostat requires a dedicated 15 AMP circuit.

4

Resistance Testing and Warranty Documentation Procedures (updated 01/01/13)Record ALL Ohm Readings on the corresponding Installation Registration Form and the Installation Plan.

I MPORTANT! IN ORDER FOR THE RADIANT SURFACES LIMITED WARRANTY TO BE VALIDATED,THE ATTACHED WARRANTY REGISTRATION FORM MUST BE COMPLETED IN FULL AND RETURNEDTO RADIANT SURFACES WITH THE YELLOW or RED TAGS ATTACHED (These tags are found attached tothe cold leads of each mat) A copy of the final installation plan (marked with any changes made in the layout of thesystem or it’s electrical connections) shall be included with the Registration Form.This information will be kept on file with our Technical Dept. so that we are better able to answer questions raisedby the distributor who purchased the product(s), the installers, the electricians, and the homeowner.

Record ALL Ohm Readings on the Warranty Registration Form (4 READINGS)

VERIFY materials shipped MATCH materials ordered BEFORE Unwrapping matsNO RETURNS ALLOWED ON MATS &/OR THERMOSTATS.

How to Measure & Record the resistance of each mat 4 TIMES DURING INSTALLATIONFIRST SET THE DIGITAL VOLT METER AT 200 SCALE SETTING

a. 120 Volts: Test between HOT (Yellow or Black) and NEUTRAL (White) b. 120 Volts: Test between Ground & HOT c. 120 Volts: Test between Ground & NEUTRAL A. 240 Volts: Test between LINE 1 (RED) & LINE 2 (BLACK) B. 240 Volts: Test between Ground & LINE 1 (RED) C. 240 Volts: Test between Ground & LINE 2 (BLACK)

Compare the reading(s) with the Ohm Reading(s) on the YELLOW or RED tags attachedto the cold leads on each mat. IF AT ANY TIME there is more than a +/- 10% differenceSTOP & CALL our Technical Department 1-925-831-1616 BEFORE CONTINUING theinstallation.

Warranty Registration Tests Record Each Measurement on the Form Attached

1. Measure & record the resistance of the mat(s) out of box. 2. Measure & record the resistance after positioning/cutting Mat(s) on the floor. 3. Measure & record the resistance after mat(s) are attached to floor with thin-set. 4. Measure & record the resistance after floor covering has been installed.

REMEMBER Place the Circuit Panel Label (example below) in the Circuit Breaker Boxto label the circuits with a description of each Radiant Surfaces mat.

5

Radiant Surfaces matuses electrical resistanceto generate heat.Resistance is measuredin units or Ohms. TheDigital Ohmmeter orMultimeter used musthave a scale capable ofreading resistance in therange of 0-200 Ohms.

CIRCUIT PANEL LABEL 1’ x 20’MANUFACTURED BY:Wuhu New Materials CoRADIANT SURFACES by WARM TILE FLOORSTYPE: TWIN CONDUCTOR U L ®120 VOLT - 60Hz 12 WATTS SQ/FT ListedMAX TEMPERATURE 175 Wuhu#SIZE: 1 ft X 20 ft = 20 SQ/FT OUTPUT: 240 WATTSPART NUMBER: C110012012Ohms Resistance = 48 +/- 10%

Sub-floor PreparationClean and inspect the sub-floor or underlayment surface carefully before laying the Radiant Surfaces mat.Remove any sharp edges or pointed objects that might damage the heating element. Repair all loose boardsand fill gaps as needed to assure that the mat will be installed over a smooth, solid surface. (Prepare the sub-floor as you would for any conventional tile installation following all TCNA Guidelines.)

Element Spacing & Coverage Recommendations

Dimension A and B should be equal when possible. Dimension A should never be less than 60% of B. DONOT ALLOW ANY HEATING ELEMENT WIRES TO OVERLAP OR ANY COLD LEAD WIRES TOCROSS, TOUCH, OR OVERLAP THE ELEMENT WIRES AT ANY POINT.

6

B

A

DO PLACE THE MAT IN OPENAREAS AND DIRECTLY INFRONT OF KEY AREAS(i.e. toilet, cabinetry, etc.)

Mat can run slightly under thebase of the toilet if need be. Itshould NEVER be placed anycloser than 4"-6" from the flange.

Mat should run directlyin front of the base ofthe vanity to heat the toekick area properly.

DO NOT HEAT UNDER ITEMSTHAT ARE FIXED TO OR FLUSHWITH THE FLOOR(i.e. toilet, cabinetry, etc.)

Customizing the Radiant Surfaces Heating MatCut the fabric mesh between the heating element wires according to the installation layout provided by yourdistributor. Fabric cutting lines are always below and between the heating element wires.

IMPORTANT! AVOID CUTTING OR NICKING ANY OF THE HEATING ELEMENT WIRES ORTHE INSULATION AROUND THEM. After cutting the desired fabric mesh, carefully and gently bendthe wire (avoiding sharp kinks) to run the next mat length in the planned direction.

DO NOT ALLOW ANY HEATING ELEMENT WIRES TO OVERLAP OR ANY COLD LEADWIRES TO CROSS, TOUCH, OR OVERLAP THE ELEMENT WIRES AT ANY POINT.

Mat Customization Illustrations USE THE SCREAMER FOR SECURITY

7

BE CAREFUL!Lift Curve of Wireto cut mesh.

DO NOT NICK OR CUT WIRES!

FULL CORNER TURN

rotate

rotate

180-DEGREE U-TURN

FAN CUT(ROUNDED CORNER)

OBSTACLE CUT 1 OBSTACLE CUT 2

flipover

OPEN CORNER TURN

rotate

flipover

column

8

INSTALLATIONImportant: Tools and materials required

You will require the following items to install and test the floor heating system:·Scissors·Utility knife·Wire strippers·Tape measure·Screwdrivers·Ohm Meter or Multi-meter (reading range 0-200 Ohms)You will also need the appropriate tools and materials to install your floor or counter. These willinclude products like self-leveling mortar, thin-set mortar, backer board, tile, a notchedtrowel, and any other tools for your specific floor. Follow these steps to ensure a successful WarmTile Floor Mat installation.Step 1: PLAN LAYOUTMake a sketch layout or a floor plan of the Room;include all permanent furnishings Such as toilets,bathtubs, appliances, cabinetry, with all dimensions.Indicate all dimensions of walls, vanities, showers toshow available floor area & the location of theOJ Thermostat

Important Radiant Surfaces will take your floor plan & completea free custom layout diagram for the most cost effectivemat sizes for your project. Send to info@warmtilefloors.comor Fax 925-838-0329.

Step 2: TRANSFER LAYOUT TO FLOORDraw an outline of the the room including a footprint of all furnishings that are not yet installed.Unroll the first few feet of the Radiant SurfacesMat. The starting point of the mat should be placedApproximately 2 to 3 ft. from the thermostatconnection.

Important

Mark the position of the factory connection between the power lead and the greenRadiant Surfaces heating cable. The connections must be concealed in thin-set or self-leveling mortar. When using a floor sensing thermostat, mark the sensor position inthe middle of the heating cable, about 10 inches (25cm) from the wall (within theheated area), as close as possible to the thermostat. Never put the sensor close to heating vents.

9

ImportantStep 3: PREPARE SUB-FLOOR SURFACEClean and vacuum floor thoroughly, removedust and debris from floor that may damage theheating cable. Ensure that the sub-floor is secureand stable. Carefully fill in all cracks to preventany potential damage to new tiles resulting fromshifts in the sub-floor. Follow Tile Councilof North America (TCNA) recommendations forproper installations for ceramic tile & stone.Step 4: MEASURE THE RESISTANCE ( 1ST TIME) BEFORE INSTALLATION, OUT OFTHE BOX BEFORE UNROLLING MATUse digital Ohmmeter or Multi-meter (capable of reading 0-200 Ohms) to measure the resistanceof the Mat and compare reading to red or yellow tag attached to the end of each mat.Record the measured resistance on the warranty sheet attached. Documenting the resistance ateach stage of installation 1-2-3-4 this is required for warranty purposes. Also, measure theresistance between the white, yellow or red and shielding/ground wire. Both should read infinity.Note: Test Sensor according to OJ Thermostat instructions & remember to install the sensorStep 5: BEGIN LAYING THE MATStart by placing the mat on the floor then makesure the temperature sensor is in the correctpositions and bring the power cable to the thermostator junction connection box. Begin unrolling themat evenly across the floor inside the areas that youmarked previously or following the layout providedby Radiant Surfaces. When you reach the next wall,cut the mesh, turn the mat, and begin rolling in thedesired direction.Step 6: VERY IMPORTANT INSTALL SENSORWhen using a OJ Floor Sensing Thermostat it isvery important to install the sensor before the floorsurfacing material. Install the sensor near theThermostat in about 10 inches placed between theheating cable on the sub-floor never touching thecables or crossing wires or cold leads.“Morgan is demonstrating placing the sensor”

10

Make sure the Radiant Surfaces Mat is in full contact with the sub-floor. Avoid walking on the mat,

use shoes with soft soles. Remember to never cut the green cable. Use staples in the mesh,

never in the cable, double sided tape or a thin strip of tape to secure the mat to the floor.

Step 7: MEASURE THE RESISTANCE ( 2nd TIME) AFTER CUSTOMIZING OR CUTTING MATPlease refer to Step 4.Step 8: MEASURE RESISTANCE ( 3RD TIME) AFTER MAT IS ATTACHED TO FLOORENSURE THAT THE SENSOR HAS BEEN PROPERLY INSTALLED BEFORE PROCEEDING(see Step 9).In the case of tiles, proceed with the installationof the tiles by covering the heating cables with alayer of thin-set mortar as directed by the tilemanufacturer. Ensure thin-set mortar covers theentire height of the heating cable as the tiles areinstalled. In the case of a wood, engineered orlaminate floor covering, it is recommended thatthe flooring manufacturer be Contacted regardingtemperature & installation method for the floor.

Step 9: Install the tileTo install the tile, apply a layer of thin-set mortar using the ridged side of your trowel. Tile &grout the floor using TCNA guidelines & best industry practices. Important

The system must not be turned on until the thin-set mortar has fully dried. A minimum of twoweeks is recommended.Step 10: MEASURE THE RESISTANCE ( 4TH TIME) AFTER FLOOR COVERING IS INSTALLED.Please refer to Step 4.To install the tile, apply a layer of thin-set mortar using the proper trowel. Tile and grout the floor usingbest industry practices and in accordance with TCNA and instructions provided by the manufacturer ofthe tile.

11

TEST 5: POWER HOOK UPPower line in Black/Red wireconnect to #2 Screw; NeutralWhite wire connect to #3 ScrewGreen ground connects to groundCold leads from Mat Yellow/Redwire connect to #1 Screw; Coldlead white wire connect to #4Screw load going to the mat infloor.

Sensor is in OJ Thermostat Box.“Test the sensor per OJ instructions”

Sensor is connected inside the O J thermostat body.Remove the screw at the bottom of the thermostat,remove cover, attach sensor wires to SENSOR IN,replace cover, tighten screw.

Don’t Forgetto Switchthe meterback to a200 ScaleSetting!

TEST 1: RESISTANCE TEST MAT OUT OF BOXTest and record element resistance of each mat on theWarranty sheet 4 times to qualify for the warranty.Don’t forget to check for shorts between the Groundand each of the other wires before proceeding. (Seedocumentation procedures outlined on page 5.)INSTALL THE MATProceed with the tile installation, making sure tofollow all TCNA Guidelines and the manufacturer’srecommendations for the tile being installed. (BECAREFUL not to snag the heating element whenapplying the thin set with the notched trowel.)NOTE: It is highly recommended that several OHMreadings be taken during the tile installation processto assure that the mat has not been damaged.TEST 2: TEST AFTER CUSTOMIZING MAT

TEST 3: TEST AFTER MAT IS ATTACHED“Test Sensor per OJ Thermostat Instructions”

INSTALL THE FLOOR COVERING

TEST 4: TEST AFTER FLOOR INSTALLEDOJ Thermostat Connection

STEP 4: CONNECT THE CONTROL(S) A qualified electrician should make all connections to the control(s) and the power source (See attached wiring diagram.) Don’t forget! The sensor wires must be connected for the thermostat to function. The system should be connected to a dedicated circuit and must be GFCI protected. NOTE: The OJ thermostat is equipped with an INTERNAL GFCI to accommodate a load <15Amps. The floor must cure for 14 DAYS BEFORE operatingTHE system.

523 San Ramon Valley Blvd, Danville, CA 94526 Phone: 925-831-1616 Fax: 925-838-0329

After the tile installation iscomplete, test and record theFINAL element resistanceof each mat. Don’t forget tocheck for shorts between theGround and each of the otherWires before proceeding.

FINAL REVIEW OF WARRANTY TEST PROCEDURES TEST 1, 2, 3, 4TEST 5 CONNECTING POWER SUPPLY AND THERMOSTAT

Basic Trouble-Shooting Guide (Updated 01/01/13)

The following are basic trouble-shooting steps that can be taken if there are problems with the Radiant SurfacesFloor Warming System. A professional electrician should be called in to trouble-shoot the system.

1. If the Radiant Surfaces Floor-Warming System fails to heat, make sure there is power delivered to the systemand the GFCI (Ground Fault Circuit Interrupter) has not been tripped. If it has, find the fault and rectify.

2. Check all of the wiring connections for the thermostat and/or timer to insure that all are connected tightly andin accordance with the wiring instruction with the thermostat. If all connections have been done properly andthe system still does not heat, proceed to Step #3.

3. Disconnect the Radiant Surfaces cold leads from the thermostat to check the resistance of each element.a. 120-Volt Product: Test between the HOT (Yellow or Black) and NEUTRAL (White).b. 240-Volt Product: Test between LINE 1 (Red) and LINE 2 (Black).

The yellow or red tag attached to the cold lead of each mat lists the Ohm Readings for that mat. Use anOhmmeter set to read resistance readings below 200 Ohms to verify that all Ohm Readings taken are within(+/ –) 10% of the Theoretical Ohm Readings listed.

· If the resistance/ Ohm Reading is zero or if it falls significantly outside of the 10% variance fromthe Theoretical reading it is likely that the heating wire was damaged. This may have been causedby damage to one of the heating elements during the installation process or by changes that were madein the floor structure (condition) after the flooring was laid. The change, no matter how slight (i.e.putting a doorstop in place, etc.) may have damaged the heating element. After locating the possibleproblem area(s), Contact Radiant Surfaces 925-831-1616, Repair Kits are available

· If the resistance/ Ohm Reading of the element(s) is found to be acceptable, but the GFCI istripping: Verify that that there is no short between the Hot (Line) and the ground. There should beno continuity. If there is continuity it is likely that the heating element is damaged and is causing ashort in the system. STOP and CALL Radiant Surfaces 925-831-1616 for further assistance.

a. 120-Volt Product: Test between the HOT (Yellow or Black) and Ground (Green) and alsobetween the NEUTRAL (White) and Ground (Green).

b. 240-Volt Product: Test between LINE 1 (Red) and Ground (Green) and also between theLINE 2 (Black) and Ground (Green).

· If the resistance/ Ohm Readings of the element(s) are found to be acceptable and the GFCI isNOT tripping, but the floor still does not heat, one of the controls may be defective. Proceed toStep #4.

4. In order to isolate the problem (to the heating element or the controls), connect the lead wires from the heatingelement (including the ground wiring), directly to power source/ GFCI. Wait approximately 60 minutes for thefloor to warm.

· If the floor temperature does not rise despite the appropriate Ohm Readings, please contact ourTechnical Dept. at 1-925-831-1616 so that we can further assist you in investigating theproblem.

· If the floor warms when connected directly to the power source/ GFCI, but does not warm when it isconnected through the controls the following may be possible:

A. One of the controls may be faulty. C. The floor sensor is not installed.B. A connection may be faulty. D. The floor sensor is not connected.

· Proceed to step #5.

5. Check for proper Voltage (120V or 240V) at the input and output connection of each control. When testingthe voltage, make sure that the controls are set to be ON. If voltage is not found in one/either of the points ofconnection on the control, it may be faulty. If you suspect that the thermostat or timer is faulty, pleasecontact Radiant Surfaces 925-831-1616 so that we can further assist you in trouble-shooting, if necessary, orarrange for exchange of the faulty product.

12