S02_Electric_Stair Heating System.pdf

RADIANT HEAT ESTIMATE Harvey-11003_RH2

Quote # …………………………..Harvey-11003_RH2 Date…………… 5/31/2023

Customer...…………..

Job Name…………..

Engineer….....…………..Brian Whitehurst Technician….. George

Category ModelQty Rough In Description Price Total

SC502400751 Yes Watts SunTouch ProMelt Cable, 75 sqft, 50W/sqft, 240V # 660.00$

SC502400651 Yes Watts SunTouch ProMelt Cable, 65 sqft, 50W/sqft, 240V # 599.60$

3006001 Yes ProMelt, PM-2B, Detector, 120/208/240V 30A # 516.80$

3006501 Yes ProMelt Display Panel, PM-DP,24V, Optional # 201.60$

1001231 Yes ProMelt Plaque # 78.30$

2004001 Yes ProMelt Heating Wire Repair Kit, 1 repair # 31.20$

Electric Snow Melting Total 2,087.50$

Wiring Diagram6 Yes Custom Wiring Diagram for System Controls # 450.00$

Project Services Total $ 450.00

Total Square Feet…………………………… 192 Radiant System Total: $ 2,537.50

Loops………………….……………………….. -

Total Number of Zones…………………………….. 1

Approximate BTU's/Hr………………………… 3,840

Pipe Feet…………………………………….. - Rough In Total: $ 2,537.50

Pipe Centers………………………………… 3

Heat Source………………………………………..

Tom Harvey

Prices listed reflect current pricing at the time of the quote, and are subject to change without notice.

Electric Snow

Melting

Electric

Project

Fort Harrison Montana Va Hospital System - Replace Exterior Stairs

Contact: Brian Whitehurst 631-240-9173

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ProMelt Cable consist of a series resistance heating cable and a single power lead for easy single-point connection. The heating mat length cannot be cut to fi t.

Engineering Specifications

Job Name ––––––––––––––––––––––––––––––––––––––––––– Contractor ––––––––––––––––––––––––––––––––––––––––––––

Job Location ––––––––––––––––––––––––––––––––––––––––– Approval –––––––––––––––––––––––––––––––––––––––––––––

Engineer ––––––––––––––––––––––––––––––––––––––––––––– Contractor’s P.O. No. –––––––––––––––––––––––––––––––––––

Approval ––––––––––––––––––––––––––––––––––––––––––––– Representative ––––––––––––––––––––––––––––––––––––––––

ProMelt Cables are available in various lengths with voltage options of 120, 208, 240, and 277 volts.

Specifications

Supply VoltageSupply Voltage

120V, 1-phase 208V, 1-phase 240V, 1-phase 277V, 1-phase

Maximum Heater CurrentMaximum Heater Current 24 Amps

Maximum Circuit Load*Maximum Circuit Load* 50 Amps

Wire SpacingWire Spacing 3" 4"

* Ground fault equipment protection is required for each circuit.

Application Parameters

Min. Bend Radius 1 inch

Max. Exposure Temperature (continuous and storage) 221ºF (105ºC)

Max. Exposure Temperature (short-term for asphalt covering) 285ºF (140ºC)

Min. Installation Temperature 40ºF (4.5ºC)

Application ProMelt Cables are used to melt ice or snow from an exterior surface and are designed for outdoor use only, embedded in concrete, asphalt, or sand.

UL Listed for U.S. and Canada under UL 515, IEEE 515.1, and CSA C22.2 No. 130-03.

Listing fi le number E483414

IN ORDER TO AVOID PROPERTY DAMAGE, INJURY AND/OR DEATH

PLEASE REFER TO THE COMPLETE INSTALLATION MANUAL AND

WARNINGS PROVIDED WITH THE PRODUCT.

Heating Density

120V 208V 240V 277V

3" Wire Spacing

50 W/sf 170 BTUh/sf

4" Wire Spacing

38 W/sf 130 BTUh/sf

Installation Parameters

Determine a time to install the cable when equipment, heavy tools, and site traffi c will be minimal. Apply the surfacing courses over the cable the same day the cable is installed.

If installing cable in the upper layer of a two-stage concrete slab or the upper layer of an asphalt application, the cable should be completely ready for the second stage. There is limited time between stages, as the slab should not be allowed to fully cure or the asphalt to completely cool. Therefore, lay out the cable and tie it to rewire that can be quickly lifted into place after the fi rst stage is laid.

If a slab sensor is installed in this second layer, plan ahead so this does not cause the fi rst layer to cure or cool too much.

Inspect the area and remove any sharp objects.

Install in temperatures at least 40°F (4.5°C).

ProMelt™ Cable Electric Snow and Ice Melt Cable

ES-ST-ProMelt Cable

NOTICE

WARNING!

SunTouch product specifications in U.S. customary units and metric are approximate and are provided for reference only. For precise measurements, please contact SunTouch Technical Service. Suntouch reserves the right to change or modify product design, construction, specifications, or materials without prior notice and without incurring any obligation to make such changes and modifications on SunTouch products previously or subsequently sold. Refer to the owner's manual for warranty information.

The information contained herein is not intended to replace the full product installation and safety information available or the experience of a trained product installer. You are required to thor-oughly read all installation instructions and product safety infor-mation before beginning the installation of this product.

NOTICE

120 VAC

Model No.

50 W/sqft

3" Spacing (Sq Feet)

38 W/sqft 4" Spacing (Sq Feet)

Cable Length (Feet)

Amp Draw Ohms

SC50120008 8 10 29 3.3 31-39

SC50120015 15 20 59 6.3 15-19

SC50120020 20 26 78 8.3 13-17

SC50120030 30 39 118 12.5 7-9

SC50120040 40 53 158 16.7 5-7

SC50120053 53 69 208 22.1 4-6

240 VAC

208 VAC

277 VAC

Junction Box

Conduit Splice not in conduit

Power Lead

Conduit 2"-6" into concrete

Concrete

Heating Cable (50.8 to 152.4 mm)

Expansion Joint

Gravel

Heating Cable

Protected to prevent concrete encasement

Sand

Concrete

ProMelt electrical leads transition from the slab to the control or electrical junction box via conduit.

ProMelt must be embedded in a sand bed when transitioning out of the concrete slab.

Model No.

50 W/sqft

3" Spacing (Sq Feet)

38 W/sqft 4" Spacing (Sq Feet)

Cable Length (Feet)

Amp Draw Ohms

SC50240015 15 20 59 3.1 64-79

SC50240025 25 33 98 5.2 46-57

SC50240030 30 39 118 6.3 30-38

SC50240040 40 53 158 8.3 26-33

SC50240045 45 59 178 9.4 20-25

SC50240055 55 72 218 11.5 18-23

SC50240060 60 79 238 12.5 14-18

SC50240065 65 85 257 13.5 12-16

SC50240075 75 98 297 15.6 11-15

SC50240080 80 105 317 16.7 10-13

SC50240090 90 118 357 18.8 9-12

SC50240105 105 137 417 21.9 8-11

Model No.

50 W/sqft

3" Spacing (Sq Feet)

38 W/sqft 4" Spacing (Sq Feet)

Cable Length (Feet)

Amp Draw Ohms

SC50208014 14 19 55 3.4 60-74

SC50208020 20 26 78 4.8 36-46

SC50208030 30 39 118 7.2 30-38

SC50208035 35 46 138 8.4 23-29

SC50208040 40 53 158 9.6 18-23

SC50208055 55 72 218 13.2 13-17

SC50208060 60 79 238 14.4 11-15

SC50208065 65 85 257 15.6 10-13

SC50208075 75 98 297 18.0 9-12

SC50208080 80 105 317 19.2 8-11

SC50208090 90 118 357 21.6 7-9

Model No.

50 W/sqft

3" Spacing (Sq Feet)

38 W/sqft 4" Spacing (Sq Feet)

Cable Length (Feet)

Amp Draw Ohms

SC50277018 18 24 59 3.1 64-79

SC50277030 30 39 98 5.2 46-57

SC50277035 35 46 118 6.3 30-38

SC50277045 45 59 158 8.3 26-33

SC50277055 55 72 178 9.4 20-25

SC50277060 60 79 218 11.5 18-23

SC50277070 70 92 238 12.5 14-18

SC50277075 75 98 257 13.5 12-16

SC50277080 80 105 297 15.6 11-15

SC50277090 90 118 317 16.7 10-13

SC50277105 105 137 357 18.8 9-12

SC50277115 115 150 417 21.9 8-11

ES-ST-ProMelt-Cable 2111 © 2021 Watts

USA: T: (888) 432-8932 • F: (417) 831-4067 • SunTouch.com Canada: T: (888) 208-8927 • F: (888) 479-2887

Latin America: T: (52) 55-4122-0138 • SunTouch.com

Installation Manual

ProMelt®

Please be aware local codes may require this product and/or the control to be installed or connected by an electrician. Please leave this manual with the end user.

Series SM & SC

Electric Snow Melting Mats & Cables

Specifications for ProMelt Cable:

ProMelt Cable is a complete heating cable consisting of a series resistance heating cable and a single power lead for easy single-point connection. The heating cable length cannot be cut to fit.

Voltages: 120, 208, 240, 277 VAC, 1-phase Watts: 50 W/ft2 (170 Btu/h/ft2), spaced at 3 inches on-center. 38 W/ft2 (130 Btu/h/ft2), spaced at 4 inches on-center (Cable is designed to operate at approximately 12.5 W/linear foot of cable at rated voltage.)

Maximum heater current: 24 amps (see table 1) Maximum circuit load: 50 amps GFEP (ground fault equipment protection) required for each circuit Listing: UL Listed for U.S. and Canada under UL 515, IEEE 515.1, and CSA C22.2 No. 130-03 Listing file number: E483414 Application: Outdoor use only, embedded in concrete, asphalt, sand (see Step 1.1) Minimum bend radius: 1 inch (25 mm) Maximum exposure temperature (continuous and storage): 221°F (105°C) Maximum exposure temperature (short-term for asphalt covering): 285°F (140°C) Minimum installation temperature: 40°F (4.5°C) Maximum continuous operating temperature (ambient): 68°F (20°C)

Specifications for ProMelt Mat:

ProMelt Mat is a complete heating mat consisting of a series resistance heating cable and a single power lead for easy single-point connection. The heating cable is pre-formed into a mat to provide consistent spacing and quick roll-out installation on the job site. The heating mat length cannot be cut to fit.

Sizes: Widths 2, 3 feet (61, 91 centimeters) Lengths 5 up to 56 feet (1.5 to 17 meters) Voltages: 120, 208, 240, 277 VAC, 1-phase Watts: 50 W/ft2 (170 Btu/h/ft2) and 38 W/ft2 (130 Btu/h/ft2) Maximum heater current: 24 amps (see table 1) Maximum circuit load: 50 amps GFEP (ground fault equipment protection) required for each circuit Listing: UL Listed for U.S. and Canada under UL 515, IEEE 515.1, and CSA C22.2 No. 130-03 Listing file number: E483414 Application: Outdoor use only, embedded in concrete, asphalt, sand (see Step 1.1) Minimum bend radius: 1 inch (25mm) Maximum exposure temperature (continuous and storage): 221°F (105°C) Maximum exposure temperature (short-term for asphalt covering): 285°F (140°C) Minimum installation temperature: 40°F (4.5°C) Maximum continuous operating temperature (ambient): 68°F (20°C)

Welcome to ProMelt® Electric Snow Melting ProMelt® products are a simple way to eliminate snow and ice from surfaces. This instruction manual is provided as a guide to installing ProMelt Mat and ProMelt Cable, including design considerations, mat and cable installation, control installation, precautions, and surfacing guidelines.

point connection. The heating cable is pre-formed into a mat to provide consistent spacing and be cut to fit.

Widths 2, 3 feet (61, 91 centimeters) Lengths 5 up to 56 feet (1.5 to 17 meters)

UL Listed for U.S. and Canada under UL 515, IEEE 515.1, and CSA C22.2

Outdoor use only, embedded in concrete, asphalt, sand (see Step 1.1)

Installation must be performed by qualified persons, in accordance with local codes, ANSI/NFPA 70 (NEC Article 426) and CEC Part 1 Section 62 where applicable. Prior to installation, please consult the local codes in order to understand what is acceptable.

To the extent this information is not consistent with local codes, the local codes should be followed. However, electrical wiring is required from a circuit breaker or other electrical circuit to the control. It is recommended that an electrician perform these installation steps. Please be aware local codes may require this product and/or the control to be installed by an electrician.

Read this Manual BEFORE using this equipment.

Failure to read and follow all safety and use information can result in death, serious personal injury, property damage, or damage to the equipment.

Keep this Manual for future reference.

Phase 1 - Designing the System Phase 2 - Preparations Phase 3 - Installation of Mat and/or Cable

Phase 4 - Finish Surfaces Phase 5 - Controls and Sensors Troubleshooting

NEVER cut or modify the heating cable. The power lead may be cut shorter if necessary, but never removed from the heating cable.

NEVER overlap or cross over the heating cable on itself, or place heating cable closer than 2 inches from another heating cable or power lead cable.

NEVER pull any of the heating cable or factory splices into any conduit.

NEVER attempt to repair a damaged cable. Contact the factory for assistance.

NEVER install the mat/cable on or under non-masonry stairs or decks made of wooden or composite materials.

NEVER install the mat/cable in the deck around a pool, in-ground hot-tub, or similar

Table of Contents

Important Safety Information

This is a safety-alert symbol. The safety alert symbol is shown alone or used with a signal word (DANGER, WARNING, or CAUTION), a pictorial and/or a safety message to identify hazards.

When you see this symbol alone or with a signal word on your equipment or in this Manual, be alert to the potential for death or serious personal injury.

This pictorial alerts you to electricity, electrocution, and shock hazards.

This symbol identifies hazards which, if not avoided, could result in death or serious injury.

This symbol identifies hazards which, if not avoided, could result in minor or moderate injury.

This symbol identifies practices, actions, or failure to act which could result in property damage or damage to the equipment.

As with any electrical product, care should be taken to guard against the potential risk of fire, electric shock, and injury to persons. The following cautions must be observed:

ALWAYS de-energize all circuits before installing or servicing.

ALWAYS completely embed the heating cable and factory splices in concrete, sand, or asphalt.

ALWAYS avoid placing the heating cable any closer than 2 inches from other items such as underground cable or piping to keep from overheating them.

ALWAYS keep ends of the power leads dry before, during, and after installation.

ALWAYS provide ground fault protection (GFEP) for the snow melting system. This may be at the circuit breaker or the control.

ALWAYS pay close attention to voltage and amperage requirements of the circuit breaker, control, and snow melting system.

ALWAYS install in accordance with all local codes and the National Electrical Code (ANSI/NFPA 70 especially Article 426) and Section 62 of the Canadian Electrical Code (CEC) Part I.

Phase 1: Designing the System Heating performance is never guaranteed.

The amount of heat required to melt snow is dependent on many factors such as air and ground temperature, wind speed, solar exposure and humidity. When designing a snow melting system, consider the expected level of performance. Systems can be designed to meet either average, or extreme weather conditions for the installation location. When determining the number of Watts per ft2 required, location specific calculations are recommended. The ASHRAE 2007 handbook is a good reference for this, with tables that include flux & Watts/ft2 data for locations throughout the USA.

If you have any questions regarding expected performance in your application, please contact the factory.

STEP 1.1

Determine general areas where you want to install ProMelt Mat/Cable Applications include driveways, walkways, patios, permanent ramps, masonry steps and benches, shipping docks, under garage door seals and more. The ProMelt Mat/Cable can be used anywhere outdoors in residential or commercial locations where snow or ice accumulates. The ProMelt Mat/Cable must be completely embedded in concrete, sand, thick mortar bed, or asphalt.

Some Typical ProMelt Installations ProMelt works well for stairs and ramps.

Garage

ProMelt Mats and Cables can be used in combination to fit a variety of areas.

Driveway with full coverage near garage and "tire track" coverage down driveway.

Entry

Garage

Entry

Garage

STEP 1.2

Measure the area where you want snow melting to occur and make a drawing. Eliminate those areas where ProMelt cannot be installed, keeping in mind the following obstructions and allowances:

• For most applications, the base under the mat/cable must be a minimum of 2 inches of masonry, asphalt, or similar material. The mat/cable must be completely covered by a minimum of 1-1/2 inches of material. (See Phase 4 Finish Surfaces for more details.)

• For a deck or similar elevated application, the mat/cable must have a minimum of 1 inch of masonry below and a minimum of 1 inch of material covering the entire mat/cable. (See Phase 4 Finish Surfaces for more details.)

• Mat/Cable cannot be laid within 6 inches of the edges of slabs. In asphalt, this is increased to 12 inches from the edge where no curb is provided.

• Avoid crossing expansion joints in a slab, unless proper technique and protection steps are followed (see Step 3.14).

• Avoid placing the heating cable any closer than 2 inches from other items such as underground cable or piping to keep from overheating them.

• Allow at least 2 inches between adjacent cables, but not more than 4 inches, between adjacent cables or sections of a mat where the mat tape is cut and turned to fill the area.

• Mat/Cable must be laid such that the surface will not have other obstructions placed on top, capturing heat or allowing potential damage from mounting brackets, bolts, or similar (pedestals, support columns, walls, light posts, hand rails, or similar)

STEP 1.3

Determine where junction box(es) may be placed to receive the ProMelt Mat/Cable power leads. This is important to ensure the mat(s) and/or cable(s) you select fill the area correctly and with the best connection locations.

It is best to locate junction boxes on a wall indoors and within the distance of the power leads on the mat/cable. ProMelt mat/ cable comes standard with 20-foot long power leads.

See typical installations on page 4.

If a junction box must be located outdoors, it is recommended it be installed above grade and be properly Listed for rain tight use outdoors. If it must be installed at or below grade, use properly Listed watertight items and follow box manufacturer guidelines for protection and connection seals.

THE HEATING CABLE CANNOT BE CUT TO LENGTH. Order the correct size mat or cable to fit the area. Modifying the heating cable is not allowed and may lead to overheating, damage, and fire hazard.

• The heating cable and factory splices of ProMelt Mat/Cable must be completely embedded in the concrete, sand, or asphalt. Never try to use up excess heating cable in surrounding soil, walls, or other unprotected applications.

• Never overlap the heating cable on itself or place heating cable closer than 2 inches from other heating cable.

• Only the power lead may exit this area. It will be pulled through conduit to protect it up to a junction box. NEVER pull any of the heating cable or factory splices into any conduit.

ProMelt Mat/Cable cannot be installed indoors, in industrial locations, or areas with hazardous classifications. It cannot be used for gutter or pipe freeze protection or roof snow melt. Do not install the mat/cable on or under non-masonry stairs or decks made of wooden or composite materials. Do not install the mat/cable in the deck around a pool, in-ground hot-tub, or similar.

See National Electrical Code article 680 and consult your local inspector for further details.

ProMelt Mat/Cable may be used to heat an outdoor area, such as a patio. This application requires special installation considerations and controls. See Step 1.6 for important control details. Only install mat/cable in concrete or mortar slab and then apply finish coverings. Never install directly in sand or similar to avoid poor performance and reduced life of the cable due to poor conductivity of dry sand and higher application temperatures.

STEP 1.4 (ProMelt Mat Only) Select the ProMelt Mat(s) you need. (for ProMelt Cable sizes see next page)

WATTAGE: Decide what heat output is required. Your design must consider weather conditions and how critical it is to clear the heated area.

• Mat with 50 watts per square foot heat output are sufficient to clear most moderate and heavy snowfall rates.

• Mat with 38 watts per square foot heat output are sufficient to clear most light to moderate snowfall rates.

SIZE: ProMelt Mat is manufactured in a variety of sizes as shown in Table 1. If the exact size of mat is not found in the Table, select the next smaller mat size.

AMPS and VOLTS: Pay careful attention to the amps to make sure your controls, circuit breaker panel, and wiring will have the proper capacity. Design everything to handle 125 percent of heating mat load:

Table 1 (mat sizes) 120 VAC ProMelt Mats (38 Watts/ft2) Size (L x W) Ft2 Model# Amps Ohms Watts

2' W id e

5' x 2' 10 SM3812000524 3.2 42-53 380

10' x 2' 20 SM3812001024 6.3 20-25 760

15' x 2' 30 SM3812001524 9.5 13-17 1140

20' x 2' 40 SM3812002024 12.7 7-10 1520

25' x 2' 50 SM3812002524 15.8 6-8 1900

30' x 2' 60 SM3812003024 19.0 4-6 2280

208 VAC ProMelt Mats (50 Watts/ft2) Size (L x W) Ft2 Model# Amps Ohms Watts

2' W id e

7' x 2' 14 SM5020800724 3.4 59-74 700

11' x 2' 22 SM5020801124 5.3 40-50 1100

14' x 2' 28 SM5020801424 6.7 28-35 1400

18' x 2' 36 SM5020801824 8.7 23-29 1800

20' x 2' 40 SM5020802024 9.6 17-22 2000

24' x 2' 48 SM5020802424 11.5 15-20 2400

28' x 2' 56 SM5020802824 13.5 13-17 2800

34' x 2' 68 SM5020803424 16.3 10-13 3400

38' x 2' 76 SM5020803824 18.3 9-12 3800

42' x 2' 84 SM5020804224 20.2 8-11 4200

48' x 2' 96 SM5020804824 23.1 7-10 4800

3' W id e

10' x 3' 30 SM5020801036 7.2 30-38 1500

15' x 3' 45 SM5020801536 10.8 14-19 2250

20' x 3' 60 SM5020802036 14.4 11-15 3000

25' x 3' 75 SM5020802536 18.0 9-12 3750

30' x 3' 90 SM5020803036 21.6 7-9 4500

240 VAC ProMelt Mats (50 Watts/ft2) Size (L x W) Ft2 Model# Amps Ohms Watts

2' W id e

8' x 2' 16 SM5024000824 3.3 68-84 800

12' x 2' 24 SM5024001224 5.0 43-54 1200

16' x 2' 32 SM5024001624 6.7 32-40 1600

20' x 2' 40 SM5024002024 8.3 26-32 2000

24' x 2' 48 SM5024002424 10.0 21-27 2400

28' x 2' 56 SM5024002824 11.7 18-23 2800

32' x 2' 64 SM5024003224 13.3 15-19 3200

36' x 2' 72 SM5024003624 15.0 13-17 3600

40' x 2' 80 SM5024004024 16.7 12-15 4000

44' x 2' 88 SM5024004424 18.3 11-14 4400

48' x 2' 96 SM5024004824 20.0 10-13 4800

52' x 2' 104 SM5024005224 21.7 8-11 5200

3' W id e

10' x 3' 30 SM5024001036 6.3 30-38 1500

15' x 3' 45 SM5024001536 9.4 20-25 2250

20' x 3' 60 SM5024002036 12.5 14-18 3000

25' x 3' 75 SM5024002536 15.6 11-15 3750

30' x 3' 90 SM5024003036 18.8 9-12 4500

35' x 3' 105 SM5024003536 21.9 8-11 5250

277 VAC ProMelt Mats (50 Watts/ft2) Size (L x W) Ft2 Model# Amps Ohms Watts

2' W id e

9' x 2' 18 SM5027700924 3.2 77-95 900

14' x 2' 28 SM5027701424 5.1 51-63 1400

18' x 2' 36 SM5027701824 6.5 36-45 1800

24' x 2' 48 SM5027702424 8.7 31-39 2400

28' x 2' 56 SM5027702824 10.1 24-31 2800

32' x 2' 64 SM5027703224 11.6 20-26 3200

36' x 2' 72 SM5027703624 13.0 17-22 3600

40' x 2' 80 SM5027704024 14.4 15-19 4000

44' x 2' 88 SM5027704424 15.9 13-17 4400

48' x 2' 96 SM5027704824 17.3 12-16 4800

52' x 2' 104 SM5027705224 18.8 11-14 5200

56' x 2' 112 SM5027705624 20.2 8-11 5600

3' W id e

10' x 3' 30 SM5027701036 5.4 55-68 1500

15' x 3' 45 SM5027701536 8.1 29-37 2250

20' x 3' 60 SM5027702036 10.8 19-25 3000

25' x 3' 75 SM5027702536 13.5 14-18 3750

30' x 3' 90 SM5027703036 16.2 11-15 4500

35' x 3' 105 SM5027703536 19.0 11-14 5250

240 VAC ProMelt Mats (38 Watts/ft2) Size (L x W) Ft2 Model# Amps Ohms Watts

2' W id e

10' x 2' 20 SM3824001024 3.2 65-81 760

20' x 2' 40 SM3824002024 6.3 31-39 1520

30' x 2' 60 SM3824003024 9.5 20-26 2280

40' x 2' 80 SM3824004024 12.7 14-19 3040

50' x 2' 100 SM3824005024 15.8 11-15 3800

60' x 2' 120 SM3824006024 19.0 9-13 4560

Site specific design calculations are recommended to ensure the system performs as expected. 38 Watt/ft2 mats are typically used in milder climates.

50 Watt/ft2 mats are better for colder climates & critical melting applications.

• 20 amp circuit for load up to 16 amps

• 30 amp circuit for load up to 24 amps

• 40 amp circuit for load up to 32 amps

• 50 amp circuit for load up to 40 amps

• 70 amp circuit for load up to 50 amps

STEP 1.4 (ProMelt Cable Only) Select the cables you need.

WATTAGE: Decide what heat output is required. Your design must consider weather conditions and how critical it is to clear the heated area. Select a cable spacing.

• 3" spacing / 50 watts per square foot (170 Btu/ft2): sufficient to clear most moderate and heavy snowfall rates

• 4" spacing / 38 watts per square foot (130 Btu/ft2): sufficient to clear most light to moderate snowfall rates

SIZE: Select a cable in Table 2 to fit the Heated Area measured in Step 1.2. ProMelt Cable is manufactured in a variety of sizes as shown. If the exact size of cable is not found in the Table, select the next smaller cable size.

AMPS and VOLTS: Pay careful attention to the amps to make sure your controls, circuit breaker panel, and all wiring will have the proper capacity. Design circuit protection and wiring to handle 125 percent of heating cable load:

Table 2 (cable sizes) Site specific design calculations are recommended to ensure the system performs as expected. 38 Watt/ft2 spacing is typically used in milder climates. 50 Watt/ft2 spacing is better for colder climates & critical melting applications.

120 VAC Cable Coverage (ft2)

3" spacing (50 W/ft2)

4" spacing (38 W/ft2) Length Model# Amps Ohms Watts

8 10 29' SC50120008 3.3 31-39 400

15 20 59' SC50120015 6.3 15-19 750

20 26 78' SC50120020 8.3 13-17 1000

30 39 118' SC50120030 12.5 7-9 1500

40 53 158' SC50120040 16.7 5-7 2000

53 69 208' SC50120053 22.1 4-6 2650

208 VAC Cable Coverage (ft2)

3" spacing (50 W/ft2)

4" spacing (38 W/ft2) Length Model# Amps Ohms Watts

14 19 55' SC50208014 3.4 60-74 700

20 26 78' SC50208020 4.8 36-46 1000

30 39 118' SC50208030 7.2 30-38 1500

35 46 138' SC50208035 8.4 23-29 1750

40 53 158' SC50208040 9.6 18-23 2000

55 72 218' SC50208055 13.2 13-17 2750

60 79 238' SC50208060 14.4 11-15 3000

65 85 257' SC50208065 15.6 10-13 3250

75 98 297' SC50208075 18.0 9-12 3750

80 105 317' SC50208080 19.2 8-11 4000

90 118 357' SC50208090 21.6 7-9 4500

240 VAC Cable Coverage (ft2)

3" spacing (50 W/ft2)

4" spacing (38 W/ft2) Length Model# Amps Ohms Watts

15 20 59' SC50240015 3.1 64-79 750

25 33 98' SC50240025 5.2 46-57 1250

30 39 118' SC50240030 6.3 30-38 1500

40 53 158' SC50240040 8.3 26-33 2000

45 59 178' SC50240045 9.4 20-25 2250

55 72 218' SC50240055 11.5 18-23 2750

60 79 238' SC50240060 12.5 14-18 3000

65 85 257' SC50240065 13.5 12-16 3250

75 98 297' SC50240075 15.6 11-15 3750

80 105 317' SC50240080 16.7 10-13 4000

90 118 357' SC50240090 18.8 9-12 4500

105 137 417' SC50240105 21.9 8-11 5250

277 VAC Cable Coverage (ft2)

3" spacing (50 W/ft2)

4" spacing (38 W/ft2) Length Model# Amps Ohms Watts

18 24 71 SC50277018 3.1 64-79 900

30 39 118 SC50277030 5.2 46-57 1500

35 46 138 SC50277035 6.3 30-38 1750

45 59 178 SC50277045 8.3 26-33 2250

55 72 218 SC50277055 9.4 20-25 2750

60 79 238 SC50277060 11.5 18-23 3000

70 92 277 SC50277070 12.5 14-18 3500

75 98 297 SC50277075 13.5 12-16 3750

80 105 317 SC50277080 15.6 11-15 4000

90 118 357 SC50277090 16.7 10-13 4500

105 137 417 SC50277105 18.8 9-12 5250

115 150 456 SC50277115 21.9 8-11 5750

• 20 amp circuit for load up to 16 amps

• 30 amp circuit for load up to 24 amps

• 40 amp circuit for load up to 32 amps

• 50 amp circuit for load up to 40 amps

• 70 amp circuit for load up to 50 amps

Always consult your electrician and designers to ensure proper sizing, location, and site capabilities.

STEP 1.5 (ProMelt Cable only) If the cable is to be laid on top of an existing slab, select enough Cable Strap to secure the cable to the surface. One box contains 25 ft. of strap, enough to secure about 50 ft2 of cable at 4-ft parallel spacing. Cable strap is usually spaced no more than 3 to 4 feet apart.

STEP 1.6

Select what level of operation is required:

1) Automatic start / timed stop melting

Snow melting system is operated as soon as snow is detected and continues for a pre-set duration. If snow remains on the sensor after the run time has expired, another melting cycle begins.

2) Automatic start & stop melting with slab temperature control Snow melting system is operated as soon as snow is detected and automatically shuts off when the sensor surface is free of snow or ice. The melting surface is operated using the lowest effective melting temperature to reduce operating costs.

3) Manual start & stop melting with slab temperature control Snow melting system is manually started at the control or using a remote enable. Snow melting operates for a timed duration or until manually shut off. The melting surface is operated using the lowest effective melting temperature to reduce operating costs.

4) Outdoor heating The surface temperature where the sensor is installed is controlled by adjusting settings in the PM-519 control. Up and down buttons are used to set the desired temperature or turn outdoor heating off.

Determine Zoning One Zone. In many instances all the areas can be heated at the same time with one control. The control can be connected to many cables and mats with multiple circuit breakers if needed. One sensor will tell the control when to operate.

Multiple Zones. In some instances it may be preferable to have some areas heated separately from other areas. This could be the case if you want to snowmelt the sidewalks in front of a store automatically first, then melt rear entrance areas manually later. In these cases, each “zone” will require its own control and sensor. Do not try to control multiple zones with one sensor.

Calculate the Amps required for each zone Total the number of Amps required by cables and mats selected for each zone.

Select a control package Zones up to 60 Amps can be controlled by an all-in-one control (PM-2C or PM-5). Zones above 60 Amps or with outdoor heating require a ContactorPro Panel and control kit combination.

System Size Operation Sensor Control Order # Required Up to 30 Amp Automatic start / timed stop melting Pole-Mount PM-2C 81011699 -

Up to 60 Amp Automatic start / timed stop melting Pole-Mount PM-5 81014247 -

Any Size Automatic start & stop melting with slab temperature control Surface-Mount PM-L3 81018910 ContactorPro Panel

Any Size Automatic start / timed stop melting Pole-Mount PM-L2 81018911 ContactorPro Panel

Any Size Manual start & stop melting with slab temperature control In-Slab PM-L1 81018912 ContactorPro Panel

Any Size Outdoor patio heating (no snow melting) In-Slab PM-519 81018840 ContactorPro Panel

ContactorPro Panel CP-50 CP-100 CP-200 Built-in Amp capacity 50 100 200

Order# 81012215 81012216 81012217

ContactorPro Panels are selected to match the Amps required. They include a 24 VAC transformer to supply power to a PM-L1, L2, L3 or PM-519 control. If 277 VAC cables are used, a separate power supply for the transformer is required.

STEP 1.7

Consult with your electrician to make sure the mats/cables, control, and design you have selected will work properly.

• The ProMelt Mat/Cable and its control must be placed on a dedicated power supply from the circuit breaker panel.

• The ProMelt Mat/Cable is a resistance heating system and should be considered as a continuous load for branch circuit sizing purposes.

• The circuit breaker must open all ungrounded conductors at the same time. A GFEP type (typically 30 mA trip) is required to directly protect the ProMelt Mat/Cable.

• Circuit breaker size and circuit wiring should be designed to 125 percent of heating mat/cable load:

- 20 amp circuit for load up to 16 amps

- 30 amp circuit for load up to 24 amps

- 40 amp circuit for load up to 32 amps

- 50 amp circuit for load up to 40 amps

- 70 amp circuit for load up to 50 amps

• Follow NEC, CEC, and local code guidelines for branch circuit wiring, conduit, and junction box installations. Outdoor and underground junction boxes and conduit must meet rain tight or watertight requirements as required.

DO NOT operate the ProMelt system in ambient temperatures above 68°F (20°C), except for a brief test to ensure system is functioning. Heating performance is never guaranteed. The amount of heat added to the area is dependent on many factors such as air and ground temperature, wind speed, solar heat, moisture, etc. If you have any questions regarding expected performance in your application, please contact the factory.

STEP 2.2

Record the mat/cable information in Table 3, on the following page. Give this information to the homeowner to keep in a safe place. The mat/cable model number, serial number, voltage, and resistance range are shown on a nameplate label attached to the power leads.

Do not use insulation underneath snow melt or exterior heated areas if vehicular traffic will be present as compression of the insulation may occur over time. Improper type or use may cause cracking of the slab and possible damage to the ProMelt Mat/Cable.

Do no attempt to install a damaged product.

Phase 2: Preparations Before installing ProMelt, make sure to fully check out the products, and carefully plan your site. The following steps may not necessarily occur in the order shown, depending on contractor and electrician scheduling and variations in site preparation requirements. A good discussion with all parties involved will help eliminate costly errors and damages.

INSPECT MAT/CABLE, CONTROL, and SENSOR

STEP 2.1

Remove the ProMelt Mat/Cable, control, and sensor from their packages. Inspect them for any visible damage and verify everything is the correct size and type according to your plan and order.

Do not remove this nameplate label. The electrical inspector will need to see this.

STEP 2.3

Use a digital multi-meter to measure the resistance between the conductors of the mat/cable power leads. Record these resistances in Table 3 under “Out of the box before installation”.

The resistance between the white lead wires should be within the resistance range on the nameplate label. If it is a little low, it may be due to low air temperatures or meter calibration. Consult an electrician or the factory if you are in doubt.

BASE MATERIAL

STEP 2.5

Prepare the site that you want to heat with ProMelt Mat/Cable This includes making sure all utilities and obstructions are accounted for.

STEP 2.6

General

Ensure the base is a smooth, well-compacted and solid base. If the mat/cable is to be placed on existing slab, inspect it for any sharp or loose objects, or other potentially damaging issues.

Ensure proper slope and drainage to avoid water buildup in any heated or surrounding areas. This is especially important for brick paver applications, as melted water may re-freeze and heave surrounding sand and paver areas.

Follow local building codes and construction guidelines for grade requirements and slab thickness in your area. Ensure that the base is at the proper height to allow the total slab thickness needed and that the cable will be embedded at the proper distance below the top surface to avoid damaging the cable. It is very important for the cable to be completely embedded.

STEP 2.7

Concrete Application

For a new pour, attach reinforcement, such as wire mesh or rebar, over the base at the required level below the top surface. You must use "chairs" or other appropriate objects to raise the wire mesh to the correct level. The ProMelt Mat/Cable will be attached to this reinforcement later. It is very important for the cable to be completely embedded in concrete.

The LoudMouth™ monitor shown at left will constantly monitor the heating wire during the entire installation process. If the wire is cut or damaged during installation, this device sounds an alarm. The LoudMouth will prevent burying a damaged wire below hardened concrete.

Megohmeters apply high voltage and could shock or cause serious injury if improperly used. Follow megohmeter instructions for safe and proper use.

The resistance between the white leads and ground lead should be “open”, usually indicated by an “OL” or whatever your meter shows when the test leads are not touching anything. If there is any change in the reading, record this information and contact the factory before installing. This could indicate damage, test lead problems, or a number of other issues. Try “pinning” the test leads to the mat/cable lead wires against a hard non-metal surface if your readings fluctuate.

STEP 2.4

Your electrician should perform an insulation resistance test on the mat. A megohmeter (e.g. Megger®) adjusted to a minimum 1000 VDC should give a measured value at least 20 megohm (MΩ). Do not apply over 1500 VDC.

Protect or remove sharp protrusions by bending them over, capping, or cutting. Sharp edges may damage the heating cable.

STEP 2.8

Asphalt Application

Apply a first course over the gravel base and compact it. The ProMelt Mat/Cable will be secured to the top of this later. Allow it to cool enough to work on before installing ProMelt Mat/Cable.

STEP 2.9

Paver or Stone Applications

Follow guidelines recommended by the paver manufacturer. If a coarse of sand is to be used to set the pavers, first lay 3/8 to 1/2 inch sand over the base to help protect the mat/cable against damage.

If this is an outdoor heating application, do not install mat/cable directly in sand or similar. The mat/cable must first be embedded in a concrete slab. Prepare the base according to Step 2.7. The pavers or stone may then be set in sand or mortar on top of this slab.

STEP 2.10

Ceramic or Stone Tile Applications

ProMelt mats or cables can be installed in the structural slab or in a thick mortar bed above a structural slab. In either case, the base material should be prepared according to section 2.7 Concrete Application.

ELECTRICAL

STEP 2.11

Install junction boxes in the location(s) planned during the design process Phase 1 (see Step 1.3).

STEP 2.12

Install conduit and branch circuit wiring from the circuit breaker panel to the control location, and from the control to the junction boxes. Follow local code for wire size, conduit requirements, and proper installation procedure.

STEP 2.13

Install conduit from the junction box to the edge of the slab to be heated. Extend this conduit into the slab edge about 2 to 6 inches and attach a bushing to the end to prevent damaging the mat/cable power leads.

• Follow electrical code for burial depth of the conduit.

• Plan carefully if you are installing edge pavers, edge drainage systems, landscaping, or other items that affect where the conduit comes in.

Table 3 - Mat/Cable Resistance Log Mat/Cable 1 Mat/Cable 2 Mat/Cable 3

Mat/Cable serial number

Mat/Cable model number

Mat/Cable voltage

Factory Mat/Cable resistance range

OUT OF THE BOX BEFORE INSTALLATION

Mat/Cable white 1 to white 2

Mat/Cable white 1 to ground

Mat/Cable white 2 to ground

AFTER MAT/CABLE IS SECURED IN PLACE

Mat/Cable white 1 to white 2

Mat/Cable white 1 to ground

Mat/Cable white 2 to ground

AFTER COVERINGS ARE APPLIED

Mat/Cable white 1 to white 2

Mat/Cable white 1 to ground

Mat/Cable white 2 to ground

Retain this log to retain the warranty! Do not discard!

STEP 2.14

If an in-slab or surface mount sensor is to be embedded in the heated area, install conduit from the control location to the desired slab location. When installing the surface mount sensor in asphalt, it is necessary to encapsulate the sensor housing in a 12"x 12" concrete pad. Follow the sensor instructions for proper placement and connections.

STEP 2.15

Install the circuit breaker size and type as determined earlier in step 1.7 (Designing the System). DO NOT connect the branch wiring to the breaker yet.

STEP 2.16

Label the circuit breaker in the panel which feeds this snow melt mat/cable system with “Snow Melt” or similar.

Phase 3: Installation of Mat and/or Cable The following Steps 3.1 through 3.12 cover installation basics. Steps 3.13 through 3.14 cover some specific applications and their special requirements.

BASIC INSTALLATION

STEP 3.1

Determine a time to install the mat/cable when equipment, heavy tools, and site traffic will be minimal to keep from possibly damaging the product. Be prepared to apply the surfacing courses over the mat/cable the same day so it will be protected from damage.

Junction Box

Conduit Splice not in conduit

Power Lead

Conduit 2"-6" into concrete

Concrete

Heating Cable

ProMelt heating cable CANNOT be cut shorter to fit!

Do not overlap or cross over heating cable on itself.

Do not space heating cable closer than 2 inches.

The heating cable and factory splices must be completely embedded in the concrete, sand or asphalt. Never try to use up excess heating cable in surrounding soil, walls or other unprotected areas.

The factory splice and heating cable can not be inside conduit.

STEP 3.2

Begin by test-fitting the mat or cable in the area to be heated. For mat, unroll it completely. Turn and flip it by cutting the tape where needed. Make sure it fits the area properly. For cable, make sure it fits the area with no excess cable.

• Mat/cable cannot be laid closer than 6 inches from the edges of slabs. In asphalt, this is increased to 12 inches from the edge where no curb is provided.

• Avoid crossing expansion joints in a slab, unless proper technique and protection steps are followed (see Step 3.14 on page 15).

• Avoid placing the heating cable any closer than 2 inches from other items such as underground cable or piping to keep from overheating them.

If installing mat/cable in the upper layer of a two-stage concrete slab or the upper layer of an asphalt application, the mat or cable should be completely ready for the second stage. There is limited time between stages, as the slab should not be allowed to fully cure or the asphalt to completely cool.

Therefore, if using ProMelt Cable, you may want to lay it out and tie it to rewire that can be quickly lifted into place after the first stage is laid. This might also be preferable for a mat installation, although if mats are precut and shaped to the area, they generally can be rolled into place fairly quickly.

• If a slab sensor is installed in this second layer, plan ahead so this does not cause the first layer to cure or cool too much.

• Inspect the area and remove any sharp objects.

Install in temperatures at least 40°F (4.5°C).

• Allow at least 2 inches, but not more than 4 inches, between adjacent mats or sections of a mat where the mat tape is cut and turned to fill the area.

• Do not repeatedly bend the heating cable, and never bend factory splices.

STEP 3.3

Place the power leads of the mat/cable next to the conduit entry. The electrician will pull this through the conduit later. Make sure it is positioned so that no part of the splice connection or the heating cable will be pulled into the conduit.

STEP 3.4

Concrete Application

ProMelt Mat: Begin laying out and securing the mat about every 2 feet to the reinforcement mesh or rebar using plastic cable ties around the heating cable. Turn the cable tie ends downward, or trim them so they will not poke up through the surface layers.

Do not use metal ties as they may damage the cable.

If installing on top of existing slab, secure the mat by nailing through the tape every 2 feet or so. NEVER strike the heating cable with a hammer.

ProMelt Cable: Begin securing the heating cable at the desired spacing to the reinforcement mesh or rebar using plastic cable ties. These cable ties should be applied at the ends of each run and at every 3 to 4 feet. Turn the cable tie ends downward, or trim them so they will not poke up through the surface layers. Do not use metal ties as they may damage the cable.

If installing on top of existing slab, secure CableStrap to the surface. Use nails or similar, every 6 to 10 inches. CableStrap should be placed at either end of the heated area, and additional straps should be applied every 3 to 4 feet in between to hold the cable in place during surfacing.

STEP 3.5

Asphalt Application

ProMelt Mat: Begin laying and securing the mat to the first course, using nails, staples or similar into the mat tape every 2 feet or so. Make sure it is laid flat. Do not use metallic nails or staples directly over the heating cable. Be careful not to damage the heating cable.

ProMelt Cable: Secure CableStrap to the surface. Use nails or similar, every 6 to 10 inches. CableStrap should be placed at either end of the heated area, and additional straps should be applied every 3 to 4 feet in between to hold the cable in place during surfacing.

STEP 3.6

Stone or Paver Application

ProMelt Mat: Begin laying out the mat and secure it onto the base with landscape fabric stakes or similar over the mat tape every 2 feet or so. Make sure it is laid flat. Do not use metallic stakes or staples directly over the heating cable. Be careful not to damage the heating cable.

ProMelt Cable: Secure plastic mounting cable ties to the gravel base, driving long nails or similar through the head of the cable tie. These cable ties should be applied at the end of each run and at every 3 to 4 feet. Do not use metallic cable ties as they may damage the cable.

Lay out the cable and secure with the cable ties.

STEP 3.7

Ceramic or Stone Tile Applications

1) Dry-set or Latex-Portland Cement (thin-set) Mortar Application – For this application, the mat or cable is installed in the concrete slab base, no less than 1.5" and no deeper than 2" below the top surface, so follow recommendations in section

3.4 for mat or cable.

2) Cement Mortar or Thick-set Application – For this application, the cable will be installed in a minimum 1.25” thick mortar bed above the structural slab.

ProMelt Mat: Begin laying out the mat and securing to the top of the slab with nails, staples, or similar through the tape every 2 feet or so. Minimum 1.25" mortar bed will be installed over the cables.

Never strike the heating cable with a hammer.

ProMelt Cable: Secure CableStrap to the surface of the slab, using nails spaced every 6 to 10 inches. CableStraps should be placed at either end of the heated area for the initial layout. Additional straps should be placed every 3 to 4 feet to hold the cables in place during application of the thick-set mortar. Minimum 1.25" mortar bed will be installed over the cables.

STEP 3.9

Use a digital multi-meter to measure the resistance between the conductors and ground wire of the mat/cable power leads again.

Record these resistances in Table 3 under “After mat/cable is secured in place”.

STEP 3.10

Feed the power leads through the conduit into the junction box, leaving at least 6 inches of free lead length. Secure the heating cable and splice so that they will not be pulled into the conduit.

Insert a generous amount of electrical conduit sealant into the conduit end around the power leads to prevent water entry

STEP 3.11

If a surface mount sensor is being installed, place the sensor socket according to the instructions included with the sensor.

Secure and seal it to the conduit installed earlier. It should be located halfway between heating cables and in an area that is recommended by the sensor manufacturer. Make sure the top of the sensor will be flush with the surface of the finish layer. Make sure it is protected with a cap or seal.

STEP 3.12

Take a photo of the mat/cable installation. This can be very helpful later for utility work, changes to the site, etc. to avoid possible damage. Keep the photos with this installation manual.

Cut

Roll Over

Rotate Rotate

Rotate Flip

Remove Mat

Fill Loose Wire in Desired Area

Move remaining Mat Up to New Position

Cut

Cut

Cut

90° or Flip Turn

Roll-over Turn

180° or Back-to-Back Turn

Fill-in Technique

Turn techniques for ProMelt Mats

Be careful not to kink or sharply bend the heating cable. A minimum bend radius of 1 inch should be maintained.

STEP 3.8 (ProMelt Mat Only) If you need to cut and turn the mat, or fill odd areas, you may use scissors to carefully cut the tape holding the heating cables.

Heating cables should be secured at about 3 inches apart, and no less than 2 inches apart.

SPECIAL APPLICATIONS

STEP 3.13

Stairs: If you are installing ProMelt Mat onto stairs, carefully cut the tape holding the heating cable. If installing ProMelt Cable, skip the previous step. Secure a single run of cable to the side of a riser. Lay 3 or 4 runs of cable on the tread area as needed and continue up each stair. Follow these guidelines:

• Lay cable no greater than 3 inches from the front edge of the finished tread. Otherwise this edge may not snow melt properly.

• Lay cable at least 6 inches from the side edges of the finished tread.

• Account for future hand railings that could be mounted onto the tread, especially in the middle of a long tread if required.

Use a marker or indicate on drawings where the railing may be installed safely later.

• Avoid pinching or sharply bending the cable. At the corner of the riser and tread, keep a minimum 1-inch radius bend, but secure it flat enough that the surface concrete or pavers will not pinch the cable.

ProMelt Mat on stairs ProMelt Cable on stairs

Expansion Joint

Gravel

Heating Cable

Protected to prevent concrete encasement

Sand

Concrete

STEP 3.14

Expansion Joints: ProMelt heating cable must never be run through an expansion joint. Doing so may cause damage to the cable with slab movement. It is recommended to lay the mat so these joints are avoided.

However, if it is necessary, a portion of the heating cable may be dropped into the grade below the expansion joint as shown. Fill around the cable with at least 1 inch thick sand. The loop of heating cable should be long enough to allow flexing, and must not be embedded into the concrete (the sand should protect against this) since this would not allow the cable to flex with slab movement.

Do not install the mat/cable on or under non-masonry stairs such as wooden or composite construction.

1-1/2" to 3" of concrete above ProMelt.

Total concrete thickness at least 4". Follow local code.

Phase 4: Finish Surfaces

STEP 4.1

Before beginning work, inspect the mat/cable for damage and secure any mat/cable that may have come loose.

To avoid burying any possible damage that may have occurred since the mat was laid, the following tests should be performed:

Use a digital multi-meter to measure and record the resistance between the conductors of the mat/cable power leads again (see Step 2.3). If possible, your electrician should perform an insulation resistance test on the mat/cable. A megohmeter (e.g.

Megger®) adjusted to a minimum 1000 VDC should give a measured value at least 20 megohm (MΩ).