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SunTouch UnderFloor Installation Manual5PART 1: Inspect the Mat and SensorMonitor the Wire!Throughout the installation processit is very important to take resistancereadings of the mat and floor sensorwires to make sure they have notbeen damaged. Use a quality digitalohmmeter (multi-meter) able to measure up to 20,000 ohms (Ω) to takethese readings. Analog meters (withthe moving needle) are not accurateenough for this product.Essential Product Informationand WarrantyDo not remove the nameplate labelfrom the power leads (see photo).Record the serial number, mat size, voltage, and mat resistance range into theresistance log below for each mat andsensor wire.To retain the Limited Warranty theseitems and the following resistancemeasurements MUST be recorded,as well as all steps of this manualfollowed. Refer now to the LimitedWarranty on our web site for completerequirements.MeasurementsAt the very least, take resistance readings (1) before beginning installation,(2) after the mat and sensor have beeninstalled in the joist bay, and (3) afterinsulation is installed.Checking for BreaksMeasure resistance between theblack and white leads and record thisbelow. This measurement should bewithin the range shown on the nameplate label. A cut or break in the wireis indicated by a resistance of “infinite”ohms (no continuity, or “OL” for “openline”).the mat resistance.If the resistance is not correct, orif the wire has been cut or damaged,note the damaged area and call thefactory for further instructions.Checking the Floor SensorThe SunStat controls come with afloor sensor. This must be tested priorto installation. Use a qualitydigital ohmmeter that is capable ofmeasuring at least 20,000 ohms (Ω),and measure between the lead wiresof the sensor. The measurement variesaccording to the temperature sensedin the tip. The sensor resistance tableon page 6 gives a set of approximatevalues for comparison.If no resistance is detected, or if theresistance value is very different fromthat shown in the sensor resistancetable, check the ohmmeter first tomake sure it was correctly set. Thencontact the factory for assistance.Checking for Short-CircuitsMeasure resistancesTo retain the Limited Warranty, resistance readings and other data MUST be recorded in theMat and Sensor Resistance Log below.Measure resistances between theblack and green leads and betweenthe white and green leads and recordthese below. These measurementsshould be “infinite” ohms (no continuityor “OL” for “open line”). A cut or pinchin the wire is indicated by a resistancevalue greater than zero but less thanMAT AND SENSOR RESISTANCE LOGRecord the information from this nameplatelabel into the Mat and Sensor Resistance Logprovided at right. Leave this nameplate labelattached to the power leads for later inspection.This Electric Radiant Heating Warning Labelmust be cut out and taped near, or on the faceof the control.MAT 1MAT 2Mat Serial NumberMat SizeMat VoltageFactory Mat Resistance RangeOUT OF THE BOX BEFORE INSTALLATION (ohms)Mat black to whiteMat black to greenMat white to greenSensor WireAFTER SENSOR AND MAT ARE INSTALLED IN JOIST BAY (ohms)Mat black to whiteMat black to greenMat white to greenSensor WireAFTER INSULATION IS INSTALLED (ohms)Mat black to whiteMat black to greenMat white to greenSensor WireRETAIN THIS LOG TO RETAIN THE WARRANTY! DO NOT DISCARD!MAT 3

6SunTouch UnderFloor Installation ManualPART 2: Electrical Service Rough-inCircuit Overcurrent Protectionand GFCI ProtectionThe SunTouch mat must be protected by a ground fault circuit interrupter (GFCI). If the mats are directlypowered through the SunStat controls,these already have an integral GFCI toprotect the mats (do not install a GFCItype circuit breaker to supply a SunStatControl because the respective GFCIsmay conflict and cause problems). If adifferent type control or relay is usedthat does not have a built-in Class AGFCI, an indicating-type GFCI circuitbreaker must be used to protect themats. This GFCI breaker serves as a localdisconnect.NOTE: Follow all local buildingand electrical codes.It is recommended that the systembe installed on its own dedicated circuit, directly from the circuit breakerpanel. However, small systems maybe able to tap into an existing circuit.Consult an electrician. Make sure thereis adequate capacity for the mat(s) aswell as any other items that may usethis circuit. The mat(s) should not beinstalled in a circuit with another GFCI(breaker or outlet), lighting circuit (lowvoltage, halogen, or other types thatuse ballasts or transformers that caninterfere), or motor circuit (exhaust fan,hot tub, etc.) due to possible interference which can cause the GFCI on thecontrol to false-trip.The circuit breaker protecting themat(s) must be no larger than 20 amps.Load the circuit breaker with no morethan the following: 12 amps on a15-amp circuit breaker, 16 amps on a20-amp circuit breaker. Additionalcircuit breakers will be required forlarger loads than these.Select mats so that no more than15 amps are run through a SunStatcontrol.Large Systems on oneFloor-sensing ControlContact the factory for more information on systems that are too largeto directly power through one SunStat,but must be operated by one floorsensing control.Install Electrical BoxesSunStat box. Decide on thelocation for the floor-sensing control.Usually this will be in the same room asthe floor being warmed, but it can bemounted almost anywhere as long as itis not in a confined space where airflowis restricted. To reach this box with themats, the mat power leads and the sensor wire leads can both be extended ifneeded with the appropriate size wireat a junction box.The control electrical box may be asingle-gang plastic deep box, but besure to follow all electrical code requirements for box fill, grounding, etc. whendetermining the correct box for a particular application.The control box should be locatedon interior walls, typically 50” to 60”from the floor, according to coderequirements.NOTE: The SunStat sensor wirecan be up to 50 ft. long, extendedwith 22- or 24-AWG wire.Other junction boxes: It is highlyUnderFloor Mat Sizes, AmperageDraw, and Resistance Ranges.AmperageResistanceMat SizeDrawRange (ohms)120 VAC16” x 4 ft.0.4258–31516” x 6 ft.0.6173–21116” x 8 ft.0.8126–15416” x 9.5 ft.1.0101–12316” x 12 ft.1.382–10116” x 14 ft.1.569–85recommended that a separate steelelectrical junction box be mountedbelow the subfloor or in the wall in alocation to which the mat power leadscan be routed. A separate wiring dropcan be made from the control boxdown to this junction box. This makesit much easier to install the system.These boxes must remain accessible,not behind a cabinet or above a drywallceiling, etc.Floor Sensor Resistance ValuesTemperatureTypical Values55 F (13 C)17,000 ohms65 F (18 C)13,000 ohms75 F (24 C)10,000 ohms85 F (29 C)8,000 ohms

SunTouch UnderFloor Installation Manual7Angled hole drilledfor floor sensorFloor surfaceSubfloorSensor tipBead of constructionadhesiveMinimum 1”-thickinsulationFloor joistInsulation (6” square)Diagram showing Method 1 for installing the floor sensor into the subfloor.Bottom Plate WorkDrill a hole up through the wallbottom plate to route the power wiring from the SunStat control box to themats below the floor.Rough-in WiringInstall electrical wiring from thepower source breaker to the SunStatcontrol electrical box, and then to thejunction box below the floor for themat leads. Leave 6”–8” of extra wire atthe control box and junction box. Referto the wiring diagrams in Part 6 forassistance.Install SunStat SensorA floor sensor comes with theSunStat control and must be installedcorrectly to control the floor temperature. Remember to locate the sensor ina floor where a mat is located. The following are recommended methods forinstalling the sensor. Other equivalentmethods may be used.Before installing the sensor, makesure to test it with an ohmmeter.See page 5, “Checking the FloorSensor.”Method 1. Since a sensor may bedifficult to install in some existing floors,the sensor may be placed under thesubfloor. However, keep in mind thatthe temperature the sensor gives willnot be a true floor surface temperatureand the floor-sensing control may needto be adjusted accordingly.Drill a hole through the bottom plateof the wall to route the sensor wire.Feed the sensor wire down from thecontrol box through the floor. (A fishtape may need to be used in order todo this.)The most accurate method is to drilla 3/4”–1”-long hole at an angle intothe bottom of the subfloor (drilling atan angle prevents puncturing throughfloor surface). Locate this hole in ajoist bay directly over where a mat willbe installed, about 2” from the joist.Insert the sensor into the angled holeand seal it with adhesive. Insulate thesensor with additional “blueboard” orfiberglass insulation, 1”–2” thick and 6”square, adhered and sealed under thesensor. This will isolate the sensor fromthe heated joist space and give a truerfloor surface temperature.Method 2. If it is not possible todrill a hole to set the sensor in the subfloor, it may be held flat to the subfloorwith a nylon wire clip. Locate the sensor in a joist bay directly over wherea mat will be installed, about 2” fromthe joist. Insulate the sensor with additional “blueboard” or fiberglass insulation, 1”–2” thick and 6” square. This willhelp isolate the sensor from the heatedjoist space.Method 3. If possible, install thesensor directly into or under the floorcovering area.If the floor surface is tiled, a grout linecan be removed and the sensor laid intothis grout line.Drill a hole into the wall behind thebaseboard trim area and directly belowthe control electrical box.Feed the sensor through the knock-out,down to the hole that was drilled near thefloor, and out into the floor above wherethe heating mat will be installed.  Locatethe sensor at least 1 ft. from outside wallsand near the center of a joist space.Complete the rest of the installationbefore covering or regrouting over thesensor.Method 3: Remove the grout 1/4” to 1/2”deep. Install sensor. Reinstall grout over thesensor and sensor wire.

8SunTouch UnderFloor Installation ManualPART 3: Install the MatSee Part 6 for typical wiring diagrams.Observe the following rules, plus allother electrical/building codes and theCautions on Page 4 when installing themat(s):Do not allow the foil radiator ofthe mat to be mounted such thatit contacts metal objects such asnails, staples, metal pipes, heating ducts, and joist straps.Keep the mat at least 2” awayfrom recessed fixtures (lights,etc.), ventilation openings, andother openings.ity. These items can damage the mat,and must be removed, cut off, or bentflat against the underside of the subfloor or the side of the joist(s).Do not staple, cut, or damage thefoiled heating portion of the mat in anyway. The fiber mesh of the mat is theportion that will be used to staple themat to the joists.Do not leave the mat rolled up orbunched up in any way in the joistbay. Doing so will cause dangerousoverheating and possible damage.Mats must be installed so that theyare completely flat across the joistcavity.3.3. Measure 2” below the subfloor andmark the joists on both sides of thejoist cavity.Keep the mat at least 8” awayfrom the edges of outlet boxesand junction boxes used tomount surface lighting fixtures.Keep the mat at least 6” awayfrom heat-sensitive items such astoilet rings, flexible ducting, andother items rated less than 194 F(90 C). Consult manufacturers ofthose items.REMEMBER:Pay careful attention to areaswhere ductwork, wiring, or otheritems do not allow the mat tobe installed. Keep in mind thatwhere mats are not installed, thecorresponding floor area abovewill not get very warm.Before installing the mat, inspect alljoists as well as the underside of thesubfloor for nails, screws, or other sharpobjects that protrude into the joist cav-1.1. Measure between the floor joistswhere mat(s) will be installed. Measurethe width of the mat selected to fitbetween these joists. The differencebetween these measurements determine how much mat mesh remainsfor stapling to each side of the joists.Because the distance between floorjoists can vary, taking these measurements will help ensure the mat will becentered between the joists. It is alsoprudent to test fit the mat by holdingthe mat up into the joist cavity.2.Test fit the mat between the joists beforestapling the mat to the joists.2. If the mat begins near the rim joist,measure about 6” out from that rimjoist. This will allow enough room forthe mat power leads, and will preventunnecessary heating of the wall cavityabove the floor.4.4. To help hold up the power leadswhile installing the mat, fasten oneNailTite over the power leads5.5. Hold the mat up along one joistand begin stapling the mat mesh alongthe 2” mark from the subfloor. Stapleevery 4” to 6” for about 2 ft. to getstarted.

SunTouch UnderFloor Installation Manual96.6. At the other end of the mat, placea nail into the joist at 2” below the subfloor. Hang the fiber mesh of the matonto the nail. This will make it mucheasier to staple the rest of the mat.9.9. Using the same techniques, staple up all other mats.Power Lead Installation7.7. Continue stapling the mat meshat 2” below the subfloor, every 4” to 6”.Then remove the nail at the end thatheld it up.If not already done so, mount a junction box below the subfloor withinreach of the mat power leads. Installmore than one junction box, if needed,for larger jobs. The junction box mustremain accessible in accordance withelectrical codes, so consider the location of the junction box carefully shouldthe ceiling be finished after installationof the mat(s).Route the power leads from themat(s) to the junction box followingall electrical and building codes usingconduit and additional electrical boxeswhere required.For multiple mats, follow all electrical codes concerning “box fill” maximums. Connect the leads in parallel(black-to-black, white-to-white), andnot in series.Connect the mat leads to the powerdrop from the control electrical box.Again, do not overload the control.The SunStat control must not be loaded with over 15 amps of mats.8.8. Raise the mat to the other joist andstaple the mat mesh 2” below the subfloor.Junction box with multiple sets of mat lead wires, connected in parallel, and connected to theSunStat control above.

10SunTouch UnderFloor Installation ManualPART 4: Final WiringInstall the ControlInstall the control(s) for the matsaccording to the wiring diagrams provided with the controls.Connect the power supply leads, thepower drop to the mat junction box,and the floor sensor wire to the SunStat.Follow proper wiring procedures.It is a good idea to overwrap thewire nuts with electrical tape to furthersecure the wires into the wires nutsbefore pushing the control back intothe electrical box.Test the Systemvided with the SunStat for propersetting.Without floor insulation, the mat willnot heat the floor. When the SunStatcalls for heat to the mat, the mat willbegin to feel warm to the touch within1 to 2 minutes or so. If this does notoccur, recheck the SunStat settings, wiring connections, and power supply.Apply the Warning LabelApply the Radiant Heating WarningLabel (pg. 5) to the control or nearbylocation.After the controls are installed andconnected, energize the system brieflyto test operation of all components.Refer to the installation sheets pro-PART 5: Install the InsulationInstall R-13 to R-19 fiberglass insulation below the mat. Gently press theinsulation up to the mat for best resultsand secure in place with rods, staples,or other method. A gap between theinsulation and mat is acceptable butwill not give the best heating results.Make sure to insulate at the end ofall heated joist cavities. Install insulation vertically in these areas to sealthe ends of the heated joist areas or,6” after the mat “stops” in a joist space,push the insulation up tight against thesubfloor and staple to the subfloor. Thisensures that no heated air can escapefrom the heated joist space.If this is not done, much heat will“escape” horizontally through bandjoists, rim joists, exterior walls, andopen ends of joist spaces, and the floorwill not warm as it should.Seal openings around pipes, wastelines, ducts, joist blocking, and all othergaps with silicone caulking or urethanefoam.The mat power leads and sensor wire connectedto the control at the electrical box.REMEMBER: Proper insulating and sealing of the floor cavity is necessary forthe performance of SunTouch UnderFloor mats.

SunTouch UnderFloor Installation ManualPART 6: Wiring DiagramsGround11UnderFloor Mat(maximum 15 amps)120 VACTypical Electric Wiring Diagram with SunStatControl (120V)SunStat ControlDedicated 120-V, 20-amp (maximum) circuit for 120VmatsLoad1 (must be GFCI protected unless a GFCI SunStat is used).BlackLine 1BlackBlackSensor Wire(no polarity)120 VACLine 2WhiteWhiteGroundLoad 2White120 VACSunStat ControlUnderFloor Mat(maximum 15 amps)Load 1BlackLine 1BlackBlackSensor Wire(no polarity)120 VACLine 2WhiteWhiteLoad 2WhiteConnectingGround two matsUnderFloor Mat(maximum 15 amps)120/240 VACSunStat ControlLoad 1BlackGroundBlackLine 1BlackWhiteConnectingtwo matsLine 2Black120 VACBlack120 VACWhiteor 240 VACWhiteLoad 1Load2BlackWhiteLoad 2White120 VACSunStat Control120/240VACLoad1SunStatControlBlackLine 1BlackLine 1BlackLoad 1BlackLine 2WhiteLine 2WhiteLoad 2WhiteLoad 2WhiteSensor Wire(no polarity)Two or more120 VAC(maximum 15 amps)Sensor Wire(no polarity)WhiteLine 1CAUTION: BlackMake sure 120 VAC Blackis supplied to 120VAC mats and120 VAC240VAC is supplied to 240VACmats. Otherwise,Line 2White dangerousGroundWhiteoverheatingand possible firehazard can result.Ground120 VACSunStat ControlSensor Wire(no polarity)120 VAC or 240 VACSensor Wire(no polarity)UnderFloor Mat(maximum 15 amps)Two or more120 VAC(maximum 15 amps)CAUTION: Make sure 120 VACConnectingtwomatsmatsis supplied to 120VACand240VACworkis supplied240VACAll electricalmusttobedone by a qualified licensed electrician in accordance with local building and electrical codes, andmats. Otherwise,dangerousthe NationalElectricalCode (NEC), especially Article 424, Part IX of the NEC, ANSI/NFPA70 and Section 62 of CEC Part 1.overheating and possible firehazard can result.Ground

PART 7: Troubleshooting GuideIf problems arise with the SunTouchUnderFloor mat or its related electrical components, please consult thistroubleshooting guide. If not qualified toperform electrical work, it is highly recommended that a qualified, licensed electrician be hired.Any electrical troubleshooting workshould be performed with the powerremoved from the circuit, unless otherwise noted.Although this troubleshooting guideis provided to assist with problems experienced with a SunTouch floor-warmingsystem, results are never guaranteed.SunTouch does not assume any liabilityor responsibility for damage or injury thatmay occur from using this guide.If problems with the system persist,call the manufacturer at 888-432-8932.ProblemPossible CauseSolutionMat resistance measurement isoutside the range printed on thenameplate label.An analog ohmmeter (using a moving needle)was used to take the reading.Obtain a digital ohmmeter able to read 0 to 20,000 ohms and remeasure the resistance.If measurement shows an open or short circuit,the heating wire has been damaged.Record resistance between all wires and contact the manufacturer.If measurement is just a little low or high, roomtemperature has affected the resistance.Make the room temperature 75

Floor joist Cross bridging or blocks Insulated around outside of area Insulated underneath mat Areas with ductwork or piping may not allow mat. Insulated at ends UnderFloor mats Install mats 2” below subfloor UnderFloor mat (with 2” air gap above the mat) 4 SunTouch UnderFloor Installation Manual