Infloor Heating Cable Repair Kit - Manual (Page 2)

Part 2. Tile and Mortar
Removal
Part 3. Installing a
Direct Splice
To install a jumper splice (please see
Step 1.2), skip to Step 4.1.
Step 2.1. If not done so already, care-
fully remove the tile/stone/marble
floor covering over the damaged
cable area. Removal of the grout
around the affected tile(s) must be
done with a blunt instrument such
as a hand-held grout-removal tool.
DO NOT USE A KNIFE! Gently break
out the tile with a small hammer,
removing the fragments as the tile is
broken up.
Step 2.2. Remove enough mortar
and tile to expose about 4” to 5” of
free wire on both sides of the dam-
aged portion. Part of the wire may
be visible so that the mortar can be
removed carefully around the dam-
aged wire using the hammer and/or
chisel. Mesh can be cut with scissors
in order to free the wire.
Step 3.1. Cut out the damaged wire
location, creating two ends or leads.
If the cable being repaired is not
the jacketed heating cable, skip to
Step 3.6.
Step 3.3. Bend the cable to snap the
jacket slug completely loose at the
score.
Step 3.4. Use the heat gun (set to
HI temperature, about 1000°F) and
move the gun back and forth under
the jacket slug for about 3 to 4
seconds until it starts to loosen and
slightly shrinks at the ends.
Step 3.5. Use a glove or other pro-
tective cloth to pull off the loosened
jacket slug. Do not touch the hot
jacket slug with bare fingers. The slug
will be very hot and will burn!
Step 3.2. Use the scoring tool to
carefully score the jacket about 2”
from the end of each lead. Do this
by placing the cable lead into the
V-notch of the tool and rotating the
tool only one or two revolutions
around the cable. Do not place any
additional pressure on the tool head
to cut deeper. Let the tool apply its
own spring-loaded pressure.
Step 3.6. Loosen the braid by push-
ing back on the braid about 1/4” and
cause the ends of the heating wires
to be exposed.
Step 3.7. Bend the cable back onto
itself.
Step 3.8. Use the small screwdriver,
paper clip, fingernail, or similar blunt
instrument to pry between the braid
and make an opening through which
to pull the heating wires. Pull each
wire through the braid.
Step 3.9. Pull the braid tight to make
it into a pigtail.
Step 3.10. Use the thermal wire
strippers to carefully strip off exactly
1/2” of the insulation from the heat-
ing wires. Count the little heating
elements to make sure none were
Step 3.11. Use the digital multi-meter
and TDR at this repair location before
proceeding. Check for any additional
damage locations in the heating
cable by “looking” in both directions.
For assistance in using these instru-
ments, consult the instructions that
came with them or contact Infloor
Sales & Service SW.
Step 3.12. Slide the solder tube over
one of the heating wires.
Step 3.13. Pull the heating wires
together to overlap the heating ele-
ments of both leads. Lightly twist
the elements together to better join
them. Slide the solder tube over the
twisted elements, centering the ele-
ments between the gray adhesive
bands. If this is not done correctly,
the elements may pull out and cause
the splice to fail.
Step 3.14. Use the heat gun (set
to HI temperature, about 1000°F) to
carefully heat the solder tube. First,
heat directly under the solder ring in
the middle of the tube. IMPORTANT!
When the solder completely melts
cut off and thereby cause a hot spot
or possible failure. A fiber strand will
also be found among the heating ele-
ments. There is no need to separate
or remove this fiber strand.
2 Heating Cable Repair Kit Guidelines