ELEKTRA TuffTec 30 User manual

www.elektra.eu
• Tuf f Tec™30
• Tuf f Tec™30/400 V
TuffTec™
Instrukcja instalacji PL
Installation manual UK
ELEKTRA
Инструкция по монтажу RU
HEATING CABLES

3
Applications
ELEKTRA TuffTec™ heating cables are intended for
effective prevention of snow and ice deposition on:
• driveways, roads, footbridges, loading ramps and
parking spaces with asphalt or concrete surface,
• roofs covered with bituminous materials,
• gutters and downpipes requiring the output of
60 W/m.
Characteristics
ELEKTRA TuffTec™ heating cables feature the
following characteristics:
• high mechanical strength
– cables intended for installations characterised
by increased risk of mechanical damages
• high thermal properties
– max. operating temperature: +110°C
– max. exposure temperature (10 min): +240°C
– min. installation temperature: -25°C
• UV-Resistant
• resistance against chemical agents, including
bituminous substances.
ELEKTRA TuffTec™ cables are intended for installa-
tion in the conditions of increased risk of mechani-
cal damages, e.g. in case when concrete consolida-
tion machinery is utilized for surface works.

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Heating Cables
ELEKTRA
Due to their exceptionally high thermal properties,
as well as resistance against bituminous substances,
the TuffTec™ cables can be safely laid in asphalt.
Also, the cables can be laid on the roofs with bitu-
minous coverings.
FEP
rst insulation layer
Multi-wire
heating core
HDPE second
insulation layer
Tinned
copper braiding
UV resistant
HFFR outer sheath
Construction of the ELEKTRA TuffTec™ heating cable
Technical properties
The ELEKTRA TuffTec™ heating cables are produced
in ready-made units, manufactured in compliance
with the EN 60335-1 standard.
The ready-made units include heating cables termi-
nated with a power supply conductor.

5
• “cold” power supply conductor
• ELEKTRA TuffTec™heating cable
• connecting joint between the power supply
conductor and the heating cable
1
2
3
1
2 3
Power output 30 W/m
Power supply voltage 230 V, 400 V ~ 50/60
Hz
Cable diameter ~ 6.8 mm
Min. installation
temperature -25°C
Max. operating
temperature +110 ° C
Max. exposure
temperature (10 min.) +240 °C
Power supply conductors 1 x 4 m; 3 x 1.5 mm²
or 3 x 2.5 mm² rubber
insulation and outer
jacket
Heating cables double-core, screened,
single-side powered
Insulation double layer, FEP +
HDPE
Outer sheath UV-resistant HFFR
Rated power output
tolerance
+5%, -10%
Min. cable bending radius 3.5 D
IP rating IPX7
System certication according to ISO 9001
IQNET, PCBC
Markings CE

6
Heating Cables
ELEKTRA
Single-side powered
heating cables

Self-adhesive label
Note:
ELEKTRA TuffTec™ 30 heating cables are designed
for the rated voltage 230 V/50 Hz, and TuffTec™
30/400 heating cables – for the rated voltage 400
V/50 Hz.
Heating cables’ heating output may vary with +5%
and -10% from the nameplate values.
!
The label features the following pictograph:
Note:
Never cut the heating cable.
Never trim the heating cable, only the power sup-
ply conductor may be trimmed if required.
Never squash the “cold tail”.
Do not ever undertake on your own any attempts
to repair the heating cables, and in case any dam-
age is detected, report the damage to an ELEKTRA
authorized installer.
Never stretch or strain the cable excessively, nor
hit it with sharp tools.
Do not install the heating cables when ambient
temperature drops below -25°C.
!

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General information
Surface protection against snow
and ice deposition
When protecting external areas from snow and ice
deposition, it is required to assess the required heat
output value per m2 of the surface. Recommended
heat output depends on the regional climate condi-
tions, i.e. minimum ambient temperature, snowfall
intensity and wind strength.
Higher output is required if the heated area is:
• exposed to wind from below:
– bridges, stairs, loading ramps, overpasses
• located in a regions of intense snowfall
Ambient
temperature
Heat output
[W/ m2]
> -5°C
-5°C ÷ -20°C
-20°C ÷ -30°C
< -30°C
200
300
400
500
Note:
Never lead the end joint and the connecting joint
between the heating cable and the power supply
conductor out of the surface. Both joints must be
placed – depending on the type of surface – within
the layer of sand, dry concrete or directly in concrete.
Never bend the joint and end seal.
Heating cables must be installed according to the
Instructions.
Mains connection of the heating cables should be
performed by an authorized electrician.
Power supply conductors (”cold tails”) in asphalt
should be positioned in the protective metal in-
stallation conduit. Alternatively, power supply con-
ductors can be led out of the area where asphalt
will be poured out.
!

8
Heating Cables
ELEKTRA
Applying insulation layer to the surfaces exposed to
wind from below can improve effectiveness.
Depending on the cable spacing, it is possible to ob-
tain required output per m2of the heated area.
Cable spacing cannot drop below 5 cm.
To protect large areas against snow and ice depo-
sition, one option is application of 400 V voltage
heating cables, which would evenly load the electric
circuit. Application of such cables would also reduce
installation works, limiting the required number of
heating cables.
Heat output 30 W/m
[W/m2][cm]
300
375
430
500
600
10
8
7
6
5

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Protection of bituminous roofs, gutters
and downpipes against snow and ice
deposition
Thanks to their exceptionally high resistance against
damaging inuence of any bituminous substances,
ELEKTRA TuffTec™ heating cables are ideally suited
for the purposes of heating roofs covered with tar
paper, roof tiles or bituminous shingles.
Selection of the required heat output depends on
the regional climate conditions of the zone where
the installation is to be positioned.
It is recommended to heat gutters and roof edges
adjoining them on the width of approximately 50
cm, as well as roof channels. Effective heating
of these elements will facilitate roof outow of
melted snow, and will prevent icicles.
Tar paper-covered roofs are usually at (up to 15°)
and require higher heat output. Especially roof val-
leys and channels are exposed to snow deposition.
Heat output for the moderate climate zone
ELEKTRA TuffTec™ heating cables can be installed
in gutters or downpipes of buildings located in cold
climate zones, where it is also necessary to execute
high heat output, i.e. 60 W/m by double-laying the
cables in gutters.
Application Heat output
[W/ m2]
Roof channels 200-300
Roof edges approx. 200
Roof stretches
excessing the building’s facade approx. 300

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Heating Cables
ELEKTRA
Anti-snow and anti-ice controls
• for the protection of surfaces
ELEKTRA ETOG2 controller – max. load up to 3x16
A. For applications in extended heating systems.
ELEKTRA ETR2 controller – max. load up to 16 A,
total output of installed heating cables must not ex-
ceed 3600 W. As standard, equipped with one tem-
perature and moisture sensor with installation tube.
Controls
Properly selected control system will ensure ad-
equate operation of the heating system only during
snow and freezing rainfall. A temperature control-
ler with a temperature and moisture sensor will au-
tomatically recognize the weather conditions. The
heating system will be then kept on standby and
only switched on when actually necessary.
For this purpose, DIN-bus installed controllers
ELEKTRA ETR2, Smart ControlTec SMC and ETO2
can be utilised.

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ELEKTRA SMCG controller – max. load up to 2x16 A.
For applications in extended heating systems.
Enables remote operation via a web browser and
signaling of operating status or errors.
As standard, equipped with one temperature and
moisture sensor and an installation tube. Additional
temperature and moisture sensor can be connected
to this controller, which will enable protection of
two outdoor areas.
• for the protection of roofs, gutters
and downpipes
As standard, equipped with one temperature and
moisture sensor and an installation tube. Additional
temperature and moisture sensor can be connected
to this controller, which will enable protection of
two outdoor areas.
ELEKTRA ETR2R controller – as standard, equipped
with one air temperature sensor and moisture sen-
sor.

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Heating Cables
ELEKTRA
ELEKTRA ETOR2 controller – as standard, equipped
with one air temperature sensor and moisture sen-
sor. Additional moisture sensor can be connected to
this controller, which will enable protection of two
independent roof areas.
Additionally, in SMC and ETO2 controllers it is possi-
ble to control two indepen-dent areas, e.g. a garage
driveway and gutters, with one controller only.
ELEKTRA SMCR controller – max. load up to 2x16 A.
For applications in extended heating systems.
Enables remote operation via a web browser and
signaling of operating status or errors.
As standard, equipped with one air temperature
sensor and moisture sensor. Additional moisture
sensor can be connected to this controller, which
will enable protection of two independent roof ar-
eas.

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To maintain xed positioning of the cable and
steady spacing conforming to the calculated
values, the cables need to be attached with the ELE-
KTRA TMS installation tape (the tape should be po-
sitioned with the distances of 40 cm) or installation
mesh of 5 cm x 5 cm grid, made of Ø 2 mm wire.
The heating cable layout should be commenced
from the side of the power supply conductor,
in such a way to enable easy reach to the switch-
board.
If the cold tail needs to be extended, a heat shrink
joint must be used. Ensuring that the connection is
safely sealed.
TMS installation tape
Installation
Stage 1: Heating cable’s
installation
1) in the surface
Before commencing the installation of the system, it
is required to assess the necessary heat output per
m2, as well as calculate the required spacing of the
heating cable.
In order to calculate the required heating cable’s
spacing, apply the following formula:
a-a = S/L
where:
a-a: distances between cables,
S: surface area, for the surface heated with
the heating cable,
L: heating cable’s length.

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Heating Cables
ELEKTRA
The heating cable layout will depend from
the surface type.
Asphalt surfaces
Stages of works:
• Metal installation tape or mesh is placed on the
compacted (hard core) base, with the heating
cable attached to it – installation tape’s tongues
should be folded so that they would not straight-
en up during asphalt rolling
• Power supply conductors (”cold tails”) in asphalt
should be positioned in the protective metal
installation conduit. Alternatively, power sup-
ply conductors can be led out of the area where
asphalt will be poured out
• The 40-50 mm-thick layer of asphalt is laid out
manually – Stage 4
• The asphalt surface is rolled – Stage 4
Cross section of a driveway or road with asphalt surface
40-50 mm-thick
layer of asphalt
Temperature
and moisture sensor
in installation tube
Compacted
base
TM
ELEKTRA TuffTec
heating cable
Metal installation mesh
or ELEKTRA TMS
steel installation tape
Concrete surfaces
Concrete surfaces require epansion joints. Unreinforced
concrete slabs should be divided into expanded areas
of the surface no larger than 9 m
2
, reinforced concrete
agstones – into areas no larger than 35 m
2
. The length
of the heating cables should be selected so that they
would not cross the expansion joints. Only the power
supply conduits (“cold tails”) can cross the expansion
joints. They are to be placed in a metal protective con-
duit of the length of approx. 500 mm.

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ELEKTRA TuffTecTM
heating cable
Temperature
and moisture sensor
in installation tube
Expansion joint
Compacted
base
Concrete slab
min. 50 mm thick
Cross section of a pavement or driveway made of concrete slab
Cross section of a pavement or driveway
made of concrete slab
Reinforced concrete agstones
Heating cables can be fastened to the reinforce-
ment of the ferroconcrete agstones. Alterna-
tively, the installation mesh of 100 mm x 100 mm
grid made of Ø 4 mm wire can be applied, which
would facilitate maintaining steady spacing of the
cable, conforming to the calculated values.
Cross section of a suspended loading ramp
Unreinforced concrete surfaces
Stages of works:
• The compacted base is levelled
• ELEKTRA TMS installation tape or installation
mesh are laid on the compacted base, the heat-
ing cable is fastened to them
• The concrete slab works follow – Stage 4
ELEKTRA TuTecTM
heating cable
Roadway layer
(e.g. resin, quartz)
Reinforcement
of the f
erroconcrete
flagstone
Metal
mesh
Layer of plaster,
e.g. acrylic,
on plastering mesh
Thermal
insulation
Cross section of a suspended loading ramp
ELEKTRA TuTecTM

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Heating Cables
ELEKTRA
Applying thermal insulation layer to ferroconcrete
agstone surfaces exposed to wind operation from
below (ramps, bridges, overpasses) can improve the
system’s effectiveness.
2) on roofs covered with tar-paper,
roof tiles or bituminous shingles
Fastening cables to roofs’ edges
The grips are attached to the roof’s stretches with
pieces of heat-sealing tar paper glued across the
grips.
RE-IH-ZNTI titanium-zinc or RE-IH-1-CU copper
holders

17
Fastening cables
in roof valleys
Alluminium self-adhesive installation strips are at-
tached to the roof’s stretches with pieces of heat-
sealing tar paper glued across the strips.
Downpipes receiving water from roof valleys re-
quire heating:
• internal downpipes at the length of approx. 1 m
• external downpipes at their entire length
RT-L500-S-AL installation strip

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Heating Cables
ELEKTRA
GH-2 gutter holder
GSW-2 gutter spacing wire
(this method of installation will greatly facilitate cleaning)
DSC-2 downpipe spacing clip
DSW-2 downpipe spacing wire
Basic accessories for installation of heating cables in
gutters and downpipes:

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Stage 2: After the heating
cable has been laid
At this stage, it is necessary to undertake
the following steps:
• Stick into the Warranty Card the self-adhesive
label, positioned on the power supply conductor
of the heating cable
• In the Warranty Card, prepare a sketch of the
heating cable’s layout positioning
• Feed the power supply conductor of the heating
cable into the switchboard
• Perform the measurements of:
– heating wire resistance
– insulation resistance
The measurement results of the heating
core’s resistance should not vary from the one
given on the label value with more than -5%,
+10 % .
The heating cable insulation’s resistance, as meas-
ured with an appliance of the rated voltage 1000
V (megaohmmeter), for at least 30 seconds and
its value should not drop below 50 MΩ. Enter the
results into the Warranty Card.
After the surface has been completed, repeat
the measurements to check whether the heating
cable has not been damaged while conducting
works.
Note:
In case of planned delay in connection of the heat-
ing cable to the electrical installation, seal the
power supply cable of the heating cable against
the possibility of internal moisture penetration
using a protective cap placed on the conduit or a
heat shrinkable end cap.
!

20
Heating Cables
ELEKTRA
(brown
or black)
(yellow-green)
Power supply conductor
Ohmmeter
Megaohmmeter
(brown
or black)
(blue)
Heating wire’s resistance measurement
Insulation’s resistance measurement