WARNING Very important: Never CUT the heating cable. This could change the cable resistance and could lead to a fire. The heating cable cannot be shortened or altered to fit. An electrical product repair must be performed by a qualified person in accordance with the local and/or national code(s) effective in your region.

TOOLS REQUIRED Heat source for heat shrink tubes (e.g., lighter or heat gun)

Wire stripper

Wire cutter (e.g., pliers)

Hammer and chisel (wear safety glasses)

Utility knife

Piece of cloth

Multimeter/Ohmmeter

Megohmmeter

Hot glue

Tape measure or ruler

FREE THE CABLE WHERE THE BREAK IS LOCATEDCover the tile with a piece of cloth and break it with a hammer. Remove the broken pieces of tile to locate the break in the heating cable. Note: At this stage, determine the cause of cable failure. Using a chisel, free the heating cable from the mortar. Remove the mortar around the cable and within the perimeter of the tile that was broken. Clean this perimeter very well.

REPAIR STEPS BASED ON THE LOCATION OF THE BREAK1. To repair the heating portion of the cable (grey cable): see #1 2. To repair the mechanical joint (between the grey cable and black cable): see #23. To repair the termination point of the heating cable (end of grey cable): see #3Note: The heat shrink tubing, insulated wire, cable and braiding provided are longer than required in order to accommodate non-standard repairs. These items must therefore be cut to the desired length of repair.

1) REPAIRING THE HEATING PORTION (GREY CABLE)

a) Prepare the heating cable:i. Cut and remove the faulty section of the cable to obtain two intact segments.ii. Free the cable to a length at least 8 inches (203 mm) longer than the portion removed on one side, and 3 inches (76 mm) on the other side.

iii. Cut the heat shrink tube 1/4 in (item D) to a length at least 4 inches (102 mm) longer than the portion removed. For example, if you removed a section of 2 inches (51 mm) from the floor heating cable, you will need a heat shrink tube at least 6 inches (152 mm) long.

iv. Cut the repair braid (item C) to a length 2 inches (51 mm) longer than the portion removed. For example, if you removed a section of 2 inches (51 mm) from the floor heating cable, you will need the braid to be 4 inches (102 mm) long.

v. Slide the heat shrink and repair braid sleeve over the longest segment of cable.

b) Prepare both ends of the heating cable:i. Strip the grey sheath (outer jacket) of the heating cable 1 inch (25 mm), exposing the ground braid.ii. Push back the ground braid over the sheathed portion of the heating cable to expose the insulated conductors.iii. Strip the conductors 1/4 inch (6 mm), exposing the bare conductor.

REPAIR PROCEDURE FOR DHEHK HEATING CABLE

KIT CONTENT

Item Description

A Heat shrink solder sleeve (small)

B Heat shrink solder sleeve (big)

C Repair braid sleeve

D Heat shrink with sealant 1/4"

E Heat shrink with sealant 1/2"

F Braided cable*

G Insulated wire**

*Recommended wire stripper size to remove outer jacket is 12 AWG and conductor insulation is 20 AWG. **Recommended wire stripper size to remove conductor insulation is 20 AWG.

Section of cable to be replaced (if needed): If the section of the cable to be replaced is less than 6 inches (152 mm), use the insulated wire (item G) from the splice kit. If it is more than 6 inches (152 mm), use the braided cable (item F). In both cases, prepare the ends as described in the previous section (b).

c) Connections:i. Slide a small heat shrink with integrated solder ring (item A) on one of the conductors then insert the replacement conductor. Place the

conductors into each side of the shrink tube in such a way that the bare portions overlap at the same location as the integrated solder ring. Repeat this procedure for the other end. Using a lighter or heat gun, adequately heat the small shrink tube with integrated solder ring. Repeat this procedure for the other end to be repaired.

ii. Pull the copper braided ground wire, covering the conductors on each end of the heating cable, towards the center. Slide the repair braid sleeve (item C) over the existing splices and copper ground braid. Then stretch the repair braid in both directions to decrease the diameter and to make sure it is in contact with the copper ground braid at each end of the heating cable.

iii. Slide the black heat shrink over the repair braid, making sure it covers the grey sheath on each end of the heating cable to properly seal the repair. Using a lighter or heat gun, heat the heat shrink until it completely seals the grey sheath on each side of the heating cable.

2) REPAIRING THE MECHANICAL JOINT (BETWEEN THE GREY HEATING CABLE AND THE BLACK COLD LEAD) Preparing the heating cable and the power line:i. Cut the cables close to the mechanical joint and remove it.ii. Follow the same sequence as Section 1, except:

a) Replace the small heat shrink with integrated solder ring (item A) with the large (item B);b) Replace the small heat shrink with sealant 1/4 inch (item D) with the large 1/2 inch (item E)Note: The recommended wire stripper size to remove the cold lead conductor (black power line) is 14 AWG.

3) REPAIRING THE TERMINATION POINT (END OF GREY HEATING CABLE) Preparing the heating cable:i. Cut the defective termination point and remove it.ii. Free the heating cables from the mortar and make sure to have a minimum of 6 inches (152 mm) available for the repair.iii. Strip the grey sheath (outer jacket) 3 inches (76 mm). Note: It is recommended to strip the grey sheath 1 inch at a time.

iv. Remove each conductor wire from the ground braid with the aid of a pointed tool then cut the two conductor wires to a length of 2 inches (50 mm). The braid will remain longer.

v. Strip each insulated conductor, until it is bare, to 1/4 inch (6 mm). Twist the two bare conductors together.

WIRE STRIPPER GAUGE TABLE

vi. Slide the large heat shrink with integrated solder ring (item B) over the conductors making sure that the integrated solder ring is centered over the twisted bare conductors. Using a lighter or heat gun, adequately heat the heat shrink and integrated solder ring making sure the solder melts and the shrink provides a good seal.

vii. Wrap the ground braids around the conductors and heat shrink to the point where the conductors were soldered.viii. Slide the heat shrink (item D) pre-cut to 2-1/2 inches (63 mm) in length over the ground braiding and the splice, while leaving a

1/2 inch (12.5 mm) of heat shrink past the splice and ensuring a 1/2 inch (12.5 mm) over the grey sheath of the heating cable. This is to ensure a good seal.

ix. Using a lighter or heat gun, heat the heat shrink until there is a perfect seal above the grey sheath. Pinch the heat shrink at the end of the cable using pliers to properly seal the termination point.

4) VERIFYING THE INTEGRITY OF THE CONNECTIONS Perform a resistance reading (using a multimeter/ohmmeter) between the conductors. Additionally, validate the quality of the insulation by performing the insulation resistance test using a megohmmeter between a conductor and the ground braid. Follow the Schluter-DITRA-HEAT Installation Handbook for these verifications.

5) ANCHOR THE CABLE TO THE FLOOR Make a groove in the DITRA-HEAT matting to accommodate the repair. Anchor the repaired cable using hot glue. Make sure the repaired joint does not interfere (i.e., is sitting too high) with the laying of the replacement tile or tiles.

Schluter Systems L.P. 194 Pleasant Ridge Road, Plattsburgh NY 12901-5841 800-472-4588Schluter Systems (Canada) Inc. 21100 chemin Ste-Marie, Ste-Anne-de-Bellevue QC H9X 3Y8 800-667-8746

www.schluter.com

Model (120 V) PVC jacket (AWG)* Conductor insulation (AWG)**

DH-E-HK12011 12 27

DH-E-HK12016 12 27

DH-E-HK12021 12 25

DH-E-HK12027 12 26

DH-E-HK12032 12 24

DH-E-HK12038 12 26

DH-E-HK12043 12 25

DH-E-HK12051 12 23

DH-E-HK12064 12 26

DH-E-HK12073 12 25

DH-E-HK12083 12 24

DH-E-HK12092 12 23

DH-E-HK120102 12 22

DH-E-HK120113 12 21

DH-E-HK120134 12 20

* Recommended wire stripper size to remove PVC (outer) jacket. ** Recommended wire stripper size to remove conductor jacket.

Model (240 V) PVC jacket (AWG)* Conductor insulation (AWG)**

DH-E-HK24011 12 28

DH-E-HK24016 12 26

DH-E-HK24021 12 27

DH-E-HK24027 12 25

DH-E-HK24032 12 27

DH-E-HK24038 12 26

DH-E-HK24043 12 25

DH-E-HK24053 12 26

DH-E-HK24064 12 24

DH-E-HK24075 12 26

DH-E-HK24085 12 25

DH-E-HK240103 12 23

DH-E-HK240129 12 26

DH-E-HK240145 12 25

DH-E-HK240167 12 24

DH-E-HK240183 12 23

DH-E-HK240204 12 22

DH-E-HK240225 12 21

DH-E-HK240269 12 20

* Recommended wire stripper size to remove PVC (outer) jacket. ** Recommended wire stripper size to remove conductor jacket.

03/2

015

201

5 S

chlu

ter

Sys

tem

s L.

P.