Danfoss GX Series User manual

Installation Manual
Danfoss GX Heating Cables & M ats
Manuel d'installation
Câbles et tapis de chauffage Danfoss GX
Danfoss
G
GX
TM
BRINGING WARMTH TO LIFE

Danfoss GX Snow Melting System ......................................................................................
Danfoss GX Cable/Mat ............................................................................................................
Warnings ......................................................................................................................................
General I nstallation Guidelines ............................................................................................
Sensor Installation ....................................................................................................................
Sensor Placement .....................................................................................................................
Installing the Heating Mat/Cable ........................................................................................
Concrete Installation ................................................................................................................
Asphalt Installation ..................................................................................................................
Stonework Installation.............................................................................................................
Danfoss Warranty ......................................................................................................................
Fondeuse à neige Danfoss GX...............................................................................................
Câble/tapis Danfoss GX............................................................................................................
Mises en garde............................................................................................................................
Lignes directrices générales d'installation........................................................................
Installation du détecteur.........................................................................................................
Placement du détecteur..........................................................................................................
Installation du tapis/câble de chauffage...........................................................................
Installation dans le béton........................................................................................................
Installation dans l'asphalte.....................................................................................................
Installation dans la maçonnerie............................................................................................
Garantie Danfoss........................................................................................................................
Table of Contents
Table des Matières
1
2
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3
16
4
17
5
18
6
19
7
20
8
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11
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Danfoss GX Snow Melting System
Danfoss GX Snow Melting System
The GX Snow Melting System consists of the GX 850 Automatic Control Panel (ACP), heating
cables or heating mats and multiple digitally operated sensors which provide an economical
and efficient means of snow melting and ice protection. Built for outdoor use, the GX system
provides safety and peace of mind to homeowners and business owners alike. Engineered for
surfaces such as asphalt, concrete and paving tiles the Danfoss GX Snow Melting System is both
versatile and easy to install. The Danfoss GX Snow Melting System operates automatically by
digitally sensing moisture and temperature.
The GX System is embedded during the paving installation, such that some control and
accessories must also be installed at this time.
It is recommended to install thermal insulation below the application of the heating cables or
mats. Improved performance and efficiency will decrease overall operating costs.
CAUTION!
It is important that this equipment is only installed by qualified electricians who are familiar
with the proper sizing, installation, construction and operation of outdoor heating systems
and the hazards involved. The GX system is designed for outdoor ice and snow melting
applications only.
Note!
The installation shall be in accordance with the manufacturer's instructions and national and
local electrical codes. The installation shall be in accordance with Part 426, American National
Standard Institute / National Fire Protection Association (ANSI/NFPA70), National Electrical
Code (NEC) and Canadian Electrical Code (CEC), Part 1. You must use a ground fault
equipment protection (GFEP) device for outdoor areas.
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Connection (all voltages)
Phase - Black
Phase- White
Ground - Green
Type:
Voltage:
Output:
Heating Element Size:
Mat
Cable
Power Lead
Bending Radius:
Cable Diameter:
Conductor Insulation:
Outer Insulation:
Max. Temperature:
Min. Installation Temp.:
Danfoss GX Cable/Mat Specifications
Twin conductor
208, 240, 277, 347, 480, 600V
2
50W/sq.ft. (540W/m ) Cable 12W/ft
6.5’ (1.98 m) - 80’ (24.38 m) long x 2’ (0.61 m) wide
35’ - 545’ (10.7 - 166 m)
20’ (6.0 m)
Minimum 1.5” (3.8 cm)
1/4”(0.65 cm)
/
FEP Teflon
PVC
220°F (105ºC)
40°F (5ºC)
Snow melting cables/mats suitable for concrete, asphalt, pavers, and stonework
 Ideal for driveways, parking lots, sidewalks, stairs, ramps, loading areas and bridges
Reduces the environmental impac t of snow and ice removal by eliminating the use of fossil
fuel driven snow blowers, snowplows, rock salt and/or other chemicals
Silent, efficient, automatic and safe
Single point connection
Zero EMF’s
Genuine twenty year warranty
Danfoss GX snow melting cables are the basis of an electric snow melting system designed to ease
the snow removal process as well as lessen its environmental impact. The GX system is both
efficient and economical. It consists of twin conductor heating cables and a single point connection
with a 20’ (6m) power lead. Danfoss GX cables are CSA certified.
Danfoss GX Cable/Mat
o
o
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Caution!
Is it important to read the instructions carefully before installing the Danfoss GX
Snow Melting System.
l
l
Never cut the black heating cable;
lExtreme care must be used to ensure the GX cables are not damaged when using sharp
tools, wheelbarrows, heavy machinery and paving equipment, shovels, rakes, or other
implements. Avoid walking on the cables or mats during installation;
lIt is not recommended to install the Danfoss GX heating mats with a controller that
does not contain an integrated temperature limiter;
lThe GX mat or GX cable must be embedded in mortar or mortar mixture, concrete, sand
or similar material;
lThe power lead/heating cable connec tion and at least 1’ (30 cm) of the power lead
must be embedded in the paved surface;
lRemaining power lead should be run through the conduit
lThe power lead may be extended if required;
lDo not install the Danfoss GX cables in such a manner that two black heating
cables touch, cross or overlap;
Remember to always measure, verify and record the actual resistance throughout the
installation process:
1. Out of the box
2. After installation
3. Before pouring the sand/concrete/asphalt
4. After surface material application
Record these values in the table on page 20 and on the warranty card, failure to do so
will void the warranty;
lMeasure the resistance between two live conductors as well as the resistance between
each conductor and the ground wire.
l Danfoss recommends using a megaohmmeter to test the insulation resistance.
lRemember to check that the supply voltage matches the voltage required for your
particular Danfoss GX product;
lRemember to place the labels as instructed in this manual;
l Metal struc tures or materials used for the support of or on which the Danfoss GX is
installed must be grounded in accordance with CSA Standard C22.1, Section 10 and the
NEC.
Please consult the Danfoss Electrical Heating Division for any other questions, concerns
or advice.
For outdoor installation only;
Warnings
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General Installation Guidelines
Planning
It is recommended to sketch a plan of the layout for the heating system installation. Mat/cable
location, sensor placement, junction boxes, conduits and the location of drains and other
obstructions should be noted.
Mat Alterations
The GX heating mats can be altered to accommodate drains, obstructions or bends in the layout.
By carefully cutting the mat tape, many patterns and designs can be created The figure below
illustrates this.
Free Cable and Cable Strapping
Should the Danfoss cable strapping be used for the GX cable, follow the instructions below for
ease of installation.
Attach the Danfoss
strapping to the
ground sur face
(3’ apart)
Place the GX cable
(3” standard
spacing)
Clip the GX cable
in place
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A feeder cable for a sensor may be needed. A 50’ (15m) cable is supplied with each sensor.
Approx. 1.5’ (0.5m) of this cable should be coiled inside the bottom of the sensor tube. The
remaining cable may be lengthened. The feeder cable must be a four wire cable.
The sensor and the conduit may be installed in connection with the actual construction work
and connected at a later date. The following applies for all types of installations:
1. Ensure that the conduit is sealed when the concrete is poured.
2. The conduit must be positioned so that it is flush with the surrounding terrain. The sensor
must be placed so that the upper brass sur face is horizontal.
3. The base below the tube must be hard, e.g. a concrete tile, in order to ensure that the sensor is
not pushed into the ground if for example a vehicle runs over it. The tube is designed to be
mounted on a plate using the two screw holes inside the conduit.
4. A metal/plastic pipe, through which the sensor cable may be passed, should be run as far as
the sensor conduit.
5. Coil approx. 1.5’ (0.5m) of the sensor cable inside the conduit.
6. Place the sensor inside the tube until it is horizontally flush with the edge of the conduit and
resting on the internal collar inside the conduit. The sensor may be extracted at a later date
using the two holes found around the edge of the sensor conduit. The grooves on the outside of
the sensor should correspond with the holes in the conduit.
Installing a Sensor and a Conduit
The temperature must not exceed F °C) around the sensor/tube. A wooden block or
similar place holder may be used in the area where the tube/sensor can be placed subsequently.
The installation pipe used for the sensor cable should, in that case, be a metal tube that can
withstand high temperatures.
176° (80
Installation in Asphalt
Installation of conduit with sensor cable
Installing a Feeder Cable
(For use with Gx850 and/or ground sensors, not applicable when using DS-2B.)
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Correct placement of the sensor(s) is important for the system to work as
intended. Some basic guidelines follow:
The number of ground sensors:
1. The more sensors added to the system the better the performance.
2. The basic principle is to place one sensor where the snow/ice will appear first (for fast
detection) and one sensor where the snow/ice will disappear last (for complete melting). If it is
not obvious just place the sensors as far apart from each other as possible.
3. With only one sensor you will have to decide what is most important:
a) fast detection and activation of the system or
b) securing a complete melting of all snow/ice. A one sensor ground system will be slower
in terms of detection and activation than a two sensor ground system, where one sensor
measures the ground temperature and the other sensor measures the moisture.
4. With more than two sensors it is possible to cover problem spots where snow usually is not
detected or where snow is not completely melted when the system stops.
Placement of Ground Sensors
1. The sensor must be placed within the heated area and at least 3.3’ (1 m)
from the edge of the area, if possible.
2. The sensor must be placed in between the heating cables - a distance
of minimum 0.4” (1 cm) should be maintained between the sensor tube
and the heating cable.
3. There must be a distance of minimum 3.3ft. (1 m) between the two sensors.
Placement of Individual Ground Sensors
SensorMin. 3 ft.
0.4” (1cm)
min 3.3ft.
(1m)
Junction box
Feeder cable
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Begin by fastening the heating mat to the mesh reinforcement using tie-wraps or cable strapping.
Do not fix the heating cable of the mat in such a way that it is compressed or strained - it must be
able to move. Unroll the mat up to the point at which it is to be flipped and turned. Use the figure on
page 5 to alter the mat.
Cut the tape using scissors and rotate the mat so that it can be unrolled to cover the area next to the
already unrolled mat. Do not cut the cable! The cable can be carefully detached from the tape
and then placed as free cable. This feature can be very useful for curves and around drains or other
obstructions.
Labels:
Labels 2E or F are to be placed at the switchboard
Labels 3E and F are to be placed in the room or area where the heating mat/cable is installed
Installing the heating mat
The GX cable must be laid out with even spacing over the entire area to be heated. To ensure an
accurate and easy method of installing the GX cable it is recommended to use Danfoss cable
strapping. Attach the cable strapping to the rebar or other supporting struc ture using tie-wraps.
The strapping should be laid perpendicular to the direction the cable will be unrolled. Space the
strapping 3’ (75cm) apar t. Secure the heating cable to the cable strapping at the correct center-to-
center distance. Do not secure the cable too tightly as this may damage the cable. If not using the
cable strapping, affix the heating cable to the rebar or wire mesh using tie wraps.
Labels:
Labels 2E or F are to be placed at the switchboard
Labels 3E and F are to be placed in the room or area where the heating mat/cable is installed
Installing the heating cable
The C-C distance is the distance between the GX cables (GX mats have a preset C-C distance).
2
Standard spacing for 50W/sq.ft. (540W/m ) is 3” (7.5 cm). In a typical application the C-C distance
should not exceed 4” and be less than 3” if the cables are installed as part of a total heating system.
If the C-C distance is higher, cold spots may form on the surface and incomplete melting may occur.
Center-to-Center (C-C) distance
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Concrete Installation
When installing Danfoss GX heating cables the following should be observed:
 Begin installation as close as possible to electrical supply source. The heating cable
must not be cut or shortened or exposed to strain in the areas of the cold tail/heating
cable coupling.
 Insulation can be installed to improve efficiency of the heating system.
 When placing the sensors please see page 7.
 Special care should be taken not to damage the heating cables with tools and
machinery during the installation and application of the sur face material.
 Ensure that all sharp stones and debris are removed from the area where the heating
cables are going to be installed.
 Should the cable become damaged during the installation process it is helpful to know
the location of the cold tail/heating cable connection. Take a picture or sketch to show
where the connection/end cap is in case a fault needs to be found.
 Connection of the heating cable must be carried out by an authorized electrician.
 Note the maximum output allowed for your installation. Do not exceed it. Contact
your local Danfoss GX dealer for questions/concerns.
 Make sure the cable is not subjected to excess tension or strain. It should not cross an
expansion joint. Where expansion joints are present, separate mats/cables should be
used.
 The heating cable braid must be grounded in accordance with local electrical codes.
 Make sure when the cable is laid it is not pushed into the insulating material.
 Ensure no air pockets exist in the surface material as this can result in damage to the
cable and limit the heat transfer.
An upstream disconnect must be installed to ensure a means of de-energizing the
cable or mat.
At low temperatures, the heating cable stiffens and may be difficult to work with.
To overcome this, connect the cable to the mains for a brief period of time. Ensure the
cable is fully rolled out when this is done.
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