Heatizon systems Cozy heat sr User manual

www.heatizon.com

HEATIZON SYSTEMS

RADIANT HEATING AND SNOW MELTING SYSTEMS

Cozy Heat® is a Registered Trademark of Heatizon Systems

01-15

Self Regulating Cable

Table Of Contents:

Product Overview………………………………………………………………..…………………….………….1

Cable Specifications……………………………………………………………………………………………. 2

Cable Diagrams………………………………………………………………..……………….…………...…….3

Warnings and Reminders………………………………………………………………….…………………….4

Design and Installation………………………………………..…………………………………………..…….5

Resistance Recording Page……………………………………………………………………………………10

Warranty…………………………………………………………………..……………………………..………..11

Cozy Heat® SR Specifications

120V and 277V

Connection

Phase Conductor

Neutral Conductor

Ground Shield

208, 240 and 480V

Connection

Phase Conductor

Ground Shield

Electrical Connection Wiring

Required Tools:

2500 VDC Megohmmeter

Digital Multimeter (DMM)

Screwdrivers

Wire Stripper

Crimping tool

Utility Knife

Heatshrink Heating device

Note: It is important that Cozy Heat® be in-

stalled only by a qualified individual who is famil-

iar with the proper sizing, installation, construc-

tion and operation of floor warming systems and

the hazards involved. Cozy Heat® products are

designed for under floor heating purposes only.

Note: Cozy Heat® must be installed in accord-

ance with the manufacturer’s installation instruc-

tions, as well as the National Electric Code

(NEC) or Canadian Electrical Code (CEC), part

1, and local regulations.

Note: A ground fault protection device i.e. GFCI,

GFEP etc.) or a Residual Current Device (RCD)

may be required. See the NEC, CEC and/or

local building codes for details.

Note: The maximum insulation value of the floor-

ing material where Cozy Heat® is installed

should not exceed R= 1.5, There is no limit for

the insulation under the sub floor.

Sample Insulation Values

Source: Radiant Flooring Guide—2008 Edition

“Comparative R-Values of Flooring and Subfloors”

Vinyl floor tiles R = 0.200 to 0.400

Carpet, Standard (Some may be compatible) R = 0.700 to 2.100

Ceramic Tile R = 0.250

Marble R = 0.400

Engineered Wood R = 0.250 to 0.750

Thinset Mortar R = 0.050

Note: Do not bend Cozy Heat® SR within

1.6” (40mm) of a termination or connection be-

tween the Cozy Heat® Heating Element and the

cold lead or power connection.

Watts per linear foot at

32° in iced water 5 9 12

Cable type Self Regulating (SR)

Copper bus wire 22 AWG Min

Maximum maintenance

temperature 185ºF (85ºC)

Maximum intermittent

exposure temperature

212ºF (100ºC)

T rating: T5

Voltage AC 120, 208, 240, 277

Maximum length Refer to product label

Approximate thickness/

width 0.25” x 0.50”

Bending radius 1”

Minimum spacing 2”

Standard spacing 4” to 9”

Cap Thickness 1 1/2” - 4”

Note: Cozy Heat® SR should be

stored in cool, dry location

STEP 2 COZY HEAT® SR SPECIFICATIONS

FIGURE 1

PERFORMANCE RATINGS POWER OUTPUT CURVE

BREAKER SIZING AND MAX CIRCUIT LENGTH

050 70 90 110 130 150

15A 20A 30A 40A

5GM1 If started at 40ºF

0ºF

-20ºF

300

200

180

—

270

230

—

330

—

9GM1 If started at 40ºF

0ºF

-20ºF

150

200

125

100

210

190

170

—

210

12GM1 If started at 40ºF

0ºF

-20ºF

115

150

180

145

120

—

180

165

120 Volt Breaker Sizing vs Max Circuit Length (ft)

15A 20A 30A 40A*

5GM2 If started at 40ºF

0ºF

-20ºF

660

410

360

—

560

480

—

660

—

9GM2 If started at 40ºF

0ºF

-20ºF

295

195

170

390

250

225

420

375

340

—

420

12GM2 If started at 40ºF

0ºF

-20ºF

230

150

130

305

200

175

360

300

260

—

360

240 Volt Breaker Sizing vs Max Circuit Length (ft)

Temperature, ºF

Power Output, Watts/Ft

5GM

9GM

12GM

15A 20A 30A 40A*

5GM2 If started at 40ºF

0ºF

-20ºF

505

475

420

—

650

560

—

765

—

9GM2 If started at 40ºF

0ºF

-20ºF

320

210

185

425

270

245

455

405

370

—

460

12GM2 If started at 40ºF

0ºF

-20ºF

240

155

135

315

210

180

375

310

270

—

375

208 Volt Breaker Sizing vs Max Circuit Length (ft)

15A 20A 30A 40A*

5GM2 If started at 40ºF

0ºF

-20ºF

570

355

310

—

485

415

—

570

—

9GM2 If started at 40ºF

0ºF

-20ºF

270

180

155

355

230

205

385

345

310

—

385

12GM2 If started at 40ºF

0ºF

-20ºF

220

140

125

290

190

165

340

285

245

—

340

277 Volt Breaker Sizing vs Max Circuit Length (ft)

* Appropriate sized butt splices may need to be sourced separately

Watts per linear foot at 32° in

iced water 5 9 12

Cable type Self Regulating (SR)

Copper bus wire 22 AWG Min

Maximum maintenance

temperature 185ºF (85ºC)

Maximum intermittent

exposure temperature

212ºF (100ºC)

T rating: T5

Voltage AC 120, 208, 240, 277

Maximum length Refer to product label

Approximate thickness/width 0.25” x 0.50”

Bending radius 1”

Minimum spacing 2”

Standard spacing 4” to 9”

Cozy Heat® SR Cable System

Junction Box

Power Distribution Panel

Power Cable/Ground Wire

Heatizon Relay Panel /Contactor

Panel or Junction Box

Cozy Heat® SR

Heating Element

Cold Lead (One)

Activation Device

Cozy Heat® SR Cable

Warnings Reminders

Sample Application: Cozy Heat® on Wood Subfloor Under Floor Covering

Sample Application: Cozy Heat® on Concrete Subfloor Under Acceptable Floor Covering

 Read this entire Design and Installation Manual prior to in-

stalling Cozy Heat® SR.

 Do not twist, kink, or spiral the Cozy Heat® SR.

 Always use a floor temperature sensing thermostat when

installing Cozy Heat® for floor warming. Use an ambient

temperature sensing thermostat when installing Cozy Heat®

for space heating purposes.

 Do not install Cozy Heat® in walls or ceilings.

 Cozy Heat® must be embedded in mortar, self leveling

concrete, thin set or other cementitious material.

 The minimum installation temperature is 40ºF (5ºC).

 Cozy Heat® SR Heating Element may be cut to length in the

field, but otherwise must not be altered, cut, damaged, or modi-

fied in any way.

 Use only copper wire from the distribution panel to the ther-

mostat. Size per the NEC or CEC.

 Do not allow Cozy Heat® SR Heating Element to touch or

cross other electrical conductors or gas lines.

 The maximum Watts per square foot should not exceed 15.

In the event the heat load required for space heating is great-

er than 15 Watts per square foot, call Heatizon Systems at

801-293-1232 prior to installing. Floor warming applications

are typically satisfied with 8 to 12 Watts per square foot.

 Cozy Heat® SR braided grounding shield must be grounded to

a suitable earth ground.

Always measure, verify and record the actual re-

sistance at specific points throughout the installation

process. A resistance recording page is included in

this manual for this purpose (see page 10). Compare

each reading to the ratings on the product table. If

the taken readings differ from those expected on the

product table or previously taken, do not energize

the Cozy Heat®, and call Heatizon Systems, 801-293

-1232.

Always roll the Cozy Heat® spool or uncoil the coil to

unreel the heating element. Do not pull Cozy Heat®

from the spool.

Remember to verify that the supply voltage matches

the design voltage of the Cozy Heat® product you

have purchased.

Cozy Heat® is for indoor and outdoor installations.

Product labels may note outdoor products with the

same specifications as indoor products.

Interior space heating always requires heat loss or

heat load calculations.

Metal structures or materials used to install or sup-

port the Cozy Heat® Heating Element must be

grounded in accordance with CEC in Canada, and

with the NEC in the US.

Please contact Heatizon Systems with additional

questions, 801-293-1232.

Acceptable Floor Covering

Cozy Heat® in Thin Set

Temperature Sensor

Plywood Subfloor

Insulation (Recommended)

Joists

Acceptable Floor Covering

Cozy Heat® in Thin Set

Temperature Sensor

Concrete Subfloor

Required Sleepers for

Nail-Down Floor Coverings

Required Sleepers for

Nail-Down Floor Coverings

Design and Installation

STEP 2 PLAN THE LAYOUT

Draw a sketch of the floor plan of the room where Cozy Heat® is to be installed. Include furnishings and fixtures, such as

toilets, bathtubs, appliances, cabinetry etc. The sketch should show all measurements and dimensions in order to deter-

mine the floor area available for floor warming. Determine the location for the Cozy Heat® thermostat and floor sensor.

Note: 120 and 208/240/277 thermostats must be located at least

4 feet away from shower or bathtub openings so that it cannot be

exposed to water, and so that persons in the shower or bathtub

area cannot make contact with the thermostat.

Using a chalk line or carpenter’s pencil, draw an outline of the floor area to be heated directly on the sub floor, including

permanently installed and uninstalled furnishings/fixtures.

Using your floor plan sketch, determine the desired appropriate spacing of Cozy Heat® Heating Element. Heatizon

Systems recommends 3” to 9” spacing as required to satisfy the heat loss calculation for spacing and 8 to 15 watts per

square foot for floor warming, see an authorized Heatizon Systems distributor for more details. Note that the minimum

distance between the cables cannot be less than 1 inch. Using a chalk line, mark the desired location where each run of

Cozy Heat® Heating Element will be installed using the predetermined appropriate spacing for the Cozy Heat® Heating

Element. Once the Cozy Heat® Heating Element locations are satisfactorily marked, the chalk lines can be covered with a

clear spray lacquer.

Establish the location of the connection point between the Cold Lead and the Cozy Heat® Heating Element. Remember,

The transition joint between Cozy Heat® SR Heating Element and the cold lead must be embedded in asphalt, concrete,

sand, stone, other cementitious material, or be in a junction box.

STEP 3 TRANSFER TO THE FLOOR

Ensure that the subfloor is flat and securely anchored to prevent it from moving and damaging the Cozy Heat® Heating

Element and floor covering. Carefully fill in all gaps in the securely anchored subfloor.

Clean the subfloor thoroughly, removing dust, miscellaneous debris and all other materials from the subfloor that may dam-

age the Cozy Heat® Heating Element. Eliminate protruding nails, staples, or any other objects that may damage the Cozy

Heat® Heating Element prior to installation.

STEP 1 SUBFLOOR PREPARATION

STEP 4 LAYOUT AND PREPARE FLOOR SENSOR

If a floor temperature sensor is being used, mark the sensor position between two Cozy Heat® Heating Element runs, ap-

proximately 10 inches away from the wall, and as close as possible to the thermostat.

Design and Installation

STEP 5 INSTALL SENSOR CONDUIT

When using a conduit for an in-floor sensor, install

it between the thermostat wall box and the sensor

location. It may be necessary to countersink the

conduit into the wood or concrete subfloor.

Cover the end of the conduit with tape so that the

cementitious material cannot enter it. Use a quick

drying glue or hot glue to hold the sensor conduit in

the groove and prevent it from floating up while the

cementitious material is installed.

STEP 6 MEASURE & RECORD RESISTANCE

Note: The sensor conduit must be centered

between two runs of Cozy Heat® Heating

Element, and must extend out at least 10

inches away from the wall.

Warning: Do not allow the sensor conduit to cross the Cozy

Heat® Heating Element. Do not allow the sensor head to touch

the Cozy Heat® Heating Element.

Cozy Heat®

Heating Element

Thermostat

Remove the Cozy Heat® SR Heating Element from the box. Using a

megohmmeter tester set at 2500 Vdc, check the insulation resistance

of the Cozy Heat® SR Heating Element to make certain it is greater

than 20MΩ. Confirm the megohmmeter result by measuring the re-

sistance with a Digital Multimeter and record the value measured on

Resistance Recording Table at the back of this manual.

Resistance measurement and megohmmeter testing must

be taken several times during the installation process:

Immediately upon removal from the packaging, after in-

stallation of the heating element, and after cement, or

asphalt application. Cozy Heat® SR Cable should also be

checked for electrical continuity. MEASURE AND

RECORD

RESISTANCE

Floor

Temperature

Sensor

STEP 7 INSTALL COZY HEAT® HEATING ELEMENT

STEP 8 INSTALL THE IN-FLOOR SENSOR AND END SEAL

Install the Cozy Heat® SR Heating Element so that the starting and ending connection points and any activation sensor are in

their desired locations. Make certain that the power end of the Cold Lead cable of the Cozy Heat® SR Cable has conductors

which extend back to the Cozy Heat® SR Termination Box or Heatizon Relay Panel.

Begin laying the Cozy Heat® Heating Element across the subfloor on the previously marked and evenly spaced chalk lines or

attach it to welded wire fabric for direct embedding or run in conduits. Use the grounding braid on one end to pull the Cozy

Heat® through conduits. You may use the optional construction glue, hot glue or foil tape to secure the cable to the subfloor.

Measure and record the resistance on Resistance Recording Table at the back of this manual.

Warning: Do not damage or subject the Cozy Heat® Heating Element to mechanical or shear stress.

Always avoid walking on the heating element. Never cut or damage the insulator on Cozy Heat® SR

Heating Element. In the event Cozy Heat® Heating Element is damaged, contact Heatizon Systems

at 801-293-1232 for repair options and do not cover.

Note: Heatizon recommends that photographs of the installed Cozy Heat® Heating Element be taken and/or hand

drawings documenting the layout be completed prior to installing the cementitious material and flooring materials.

Design and Installation

If the optional sensor conduit has not been installed, the In-floor sensor must be installed now. Install the in-floor sensor de-

signed for the thermostat you have selected per the manufacturer’s instructions.

Install the Cozy Heat® End Seal Kit now before embedding the cable or applying the cementitious material. The end seal kit is

included in the power connection kit or can be purchased separately. See www.heatizon.com for additional details and follow

the instructions included in the power connection or end seal kit.

MEASURE AND

RECORD

RESISTANCE

Note: the in-floor sensor must not directly cross or come into contact with the Cozy Heat® Heating Element. The in-floor

sensor should be installed between lengths of Cozy Heat® Heating Element and at least 10” from any wall.

Junction Box

Power Distribution Panel

Power Cable/Ground Wire

Heatizon Relay Panel

Contactor Panel or Junction Box

Cozy Heat® SR

Cold Lead

Activation Device

STEP 9 APPLY THE CEMENTITOUS MATERIAL

Design and Installation

Ensure that the optional sensor conduit or that the in-floor sensor have been properly installed before proceeding beyond this

point.

For stone and tiling applications

Proceed with the installation of the tiles by covering the Cozy

Heat® Heating Element with a layer of cementitous material,

as directed by the tile manufacturer. Ensure that the

cementitous material covers the entire Cozy Heat® heating

element and conduit.

For all other applications

Proceed with the applying or self-leveling cement, or other

cementitous material. Ensure that the cementitous material

covers the entire heating element and conduit before the

floor covering is installed.

Note: Consult the manufacturer of the carpet, wood (natural or engineered) or laminate floor coverings for maximum

temperature tolerances. Always use a Cozy Heat® thermostat with a floor temperature sensor for these floor coverings.

MEASURE AND

RECORD

RESISTANCE

Eliminate all moisture in the self leveling cement or other cementitous material in accordance with drying

times recommended by the manufacturer. Cozy Heat® must not be turned on until cementitous material has

fully dried (a minimum of 7 days is recommended). Once the cementitous material has dried, measure and

record resistance on Resistance Recording Table at the back of this manual. Determine that the megohms

exceed 20 with a megohmmeter tester set at 2500 Vdc.

STEP 10 CONNECT POWER SUPPLY & THERMOSTAT

The connection of the power supply and the floor sensing thermo-

stat must be done by a qualified individual in accordance with the

National Electrical Code (NEC) and the Canadian Electrical Code

(CEC). The qualified individual should also feed the sensor cable

into the installed sensor conduit and connect it to the thermostat.

The braided shield from the Cozy Heat® SR Cable must be wired

to ground for all installations.

Measure and record a final resistance reading at this stage in the installation on

the Resistance Recording Table at the back of this manual. Determine that the

megohms exceed 20 with a megohmmeter tester set at 2500 VDC.

MEASURE AND

RECORD

RESISTANCE

Example Terminal Box

Caution: Never energize Cozy Heat® SR until:

1. The Cozy Heat® SR Cable has been verified to be free of damage.

2. All splices and all power kit and end kit connections have been inspected.

3. A Megohmmeter Test has been used to verify a minimum of 20 Megohms between the heat-

ing element and the braided ground shield.

Note: The Cozy Heat® Heating Element

is designed for in floor heating and space

heating applications only. Product labeling

may cross additional brands with same

specifications as Cozy Heat® SR Cable

Design and Installation

STEP 13 COMPLETE WARRANTY CERTIFICATE

Mail in the warranty certificate for Cozy Heat® and one for the ther-

mostat immediately after installing the Cozy Heat® system. Failure

to do so could void the manufacturer’s warranty. The warranty is

subject to the guarantee conditions listed on the warranty certificate,

and upon documentation that the required resistance readings were

completed. You may wish to keep a copy of the warranty card for

your reference.

The Cozy Heat® system is now ready to use and enjoy! Adjust the floor temperature sensing ther-

mostat until the floor reaches a comfortable level for floor warming applications. For space heating

applications adjust the thermostat to your comfort level, usually 65º to 70º F.

Keep these instructions and all other owner/operating manuals for future reference.

Note: The Cozy Heat® SR Heating Element

must be embedded in a cementitious material or

installed in conduit.

STEP 12 COMPLETE AND ATTACH LABELS

Place the included labels in the following locations:

 Electrical Panel Label — Inside door at electrical service panel.

 Stop Sign Warning Label — on or near the area to be floor warmed/in- floor

heated by Cozy Heat®

Note: Make certain to record information from the Product Identification Label, if

applicable.

STEP 11 TROUBLESHOOTING

Problem: Cozy Heat® Cable fails the Megohmmeter Test

Potential Causes:

 Inspect the Cozy Heat® Cable for damage to the insulator or braided ground and/or contact

between the braided ground and the core wires. Repair the length of damaged Cozy Heat®

Cable with a splice kit or replace the entire length.

 Call Heatizon Systems technical support 801-293-1232

Note: In the event the Cozy Heat® Cable has not been damaged in any way call Heatizon Systems

technical support @ 801-293-1232. For Warranty claims, please return the entire length of Cozy

Heat® to Heatizon Systems with requested forms (RMA, Warranty, Resistance Recording), with the

end termination and power termination connections intact, for evaluation prior to replacement.

Resistance Recording Page

Use a Digital Multi Meter to measure the resistance of the Cozy Heat® Heating Element, and compare

it to the expected resistance for the product purchased. Cozy Heat® SR Cable should be tested using a

megohmmeter, set at 2500 VDC. The measured value should not be less than 20 Megohms. Record all

test results below.

Customer Warranty Information

Name

Address

City State

Phone Email

Zip

Purchased Product Details

Watts Volts Ω

Watts &

Volts Ohms

Sq. Ft.

Model Size

Serial

Number

Manufacture

Date

Tile/Stone Vinyl/Laminate Wood Carpet Other

  

Floor

Covering

Prior to Installation

(When removed from

Package)

After Installation of Co-

zy Heat® Heating

Element on Subfloor

After Thin Set or Self

Leveling Cement

Application

After Floor Covering

Material Installation

Ohms

Date Time

MEASURE AND

RECORD

RESISTANCE

Heatizon Systems Cozy Heat® SR Warranty

Mail: Heatizon Systems

4137 South 500 West

Murray, UT 84123

USA

Phone: (801) 293-1232

Toll Free: (888) 239-1232

Fax: (801) 293-3077

Email: [email protected]

Website: www.heatizon.com

How to make a Warranty Claim

1. Gather the following information:

 Date of purchase

 Who product was purchased from

 Date of installation, if installed

 Names and phone numbers of electrician/installer

 Completed resistance recording page from installation

 Serial number from product label

2. Contact Heatizon Systems for a Return Materials Authorization number, and information on the next

required steps to complete your warranty claim.

Heatizon Systems warrants Cozy Heat® Heating Element to be free from defects in material and workmanship for a period of ten (10) years and Acti-

vation Device(s) for a period of one (1) year. Such warranty periods shall commence on the date of shipment by Heatizon Systems. If any parts are

found to be defective in manufacture during such time period, Heatizon Systems will, at its sole option, replace or repair defective parts.

This Limited Warranty applies only if articles sold hereunder (a) are selected, designed, and installed according to instruction and operation manuals

furnished by Heatizon Systems and installed in a “workmanlike manner” according to the building association standards adopted by Heatizon Systems,

(b) remain in their originally installed location, (c) are connected to proper power supplies, (d) are not misused or abused, (e) show no evidence of tam-

pering, mishandling, neglect, damage (accidental or otherwise), modifications or repair without the approval of Heatizon Systems, or damage done to

the product by anyone other than Heatizon Systems, and (f) are installed in accordance with applicable code requirements. Any warranty claims must

be made in writing, no later than one (1) month following expiration of the warranty period, and must be accompanied by the warranted part or compo-

nent. Any claim not made in such manner shall not be honored by Heatizon Systems.

This Limited Warranty does not cover:

1. The workmanship of any installer of Heatizon Systems radiant panel heating products.

2, Any Heatizon Systems radiant heating products that have a failure or malfunction resulting from improper or negligent operation, installation, acci-

dent, abuse, misuse, unauthorized alteration or improper repair or maintenance.

3. Any Heatizon Systems radiant heating products that have had components not purchased from Heatizon Systems integrated into or connected to

them.

4. Any labor costs for removal of alleged defective part(s) and/or reinstallation of replacement part(s), transportation to and from Heatizon Systems (if

necessary) and any other material necessary to perform the exchange or repair.

5. Any Heatizon Systems heating products that have not been properly registered by completion and return of the Warranty Registration Card attached

hereto within ninety (90) days of the date of sale.

DISCLAIMER OF WARRANTIES:

This warranty described above is in lieu of all other warranties, express or implied, including but not limited to any implied warranties of

fitness for a particular purpose and merchantability. Heatizon Systems expressly disclaims and excludes any liability for losses, expenses, inconven-

iences, consequential, incidental, indirect, or punitive damages for breach of any express or implied warranty. By installing and/or purchasing Heatizon

Systems products, you accept the terms of this limited warranty.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an implied warranty

lasts, so the above limitations and exclusions may not apply to you. This Limited Warranty gives you specific legal rights, and you may also have other

rights which may vary from state to state.