Document YD2G5ZkaykLzrQbGZqqpMV0VV

PLAINTIFF'S EXHIBIT USG-1981 TECHNICAL HANDBOOK THERMALUX Electric Heating H-l * . wS i Ij ? u L , L- Zm Sf? s/c - . //'/,/, . 'S'. ''!/"//'; r y,/ ........ JUL 1966 00 NOT r** T" r* "'"i * Utu i r-: L. , BB029 0491 THERMALUX ELECTRIC HEATING Technical Handbook UNITED STATES GYPSUM COMPANY BB029 0492 H-l, U.5.G. Rev. \2/65 Printed in U. S. A CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 TABLE OF CONTENTS Page THERMALUX - AN IMPORTANT ADVANCE IN ELECTRIC HEATING....................... 1-1 Safety..................................................................................................................................... Comfort.............................................................................................................................. Cleanliness........................................................................................................................... Economy.............................................................................................................................. Convenience....................................................................................................................... Space Economy.................................................................................................................... Quiet..................................................................................................................................... A NEW PRODUCT FOR THOSE IN THE BUILDING TRADE....................................... 1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-1 THERMALUX SYSTEM COMPONENTS................................................................................... 2-1 U.S.G. - ONE SOURCE FOR A COMPLETE SYSTEM.............................................. Heating Panels.................................................................................................................... Filler Panels .................................................................................................................... Finishing Panels................................................................................................................ Insulated Nails.................................................................................................................... Branch Circuit Bushings.................................................................................................. Electrode Connectors...................................................................................................... Controls.............................................................................................................................. THERMALUX Adhesive.................................................................................................. THERMALUX Joint Finishing Materials................................................................... Complementary Products............................................................................................... THERMALUX SYSTEM DESIGN........................................................................................ 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-2 2-3 2-3 HEAT SOURCE FUNDAMENTALS........................................................................................... 3-1 ENERGY..................................................................................................... 3-1 Power................................................................................................................................. 3-1 ENERGY CONVERSION........................................................ 3-1 TRANSFER OF ENERGY...................................................................................................... 3-2 GENERATION OF HEAT...................................................................................................... 3-2 HOW HEAT IS TRANSFERRED........................................................................................... Conduction........................................................................................................................... Convection..............................................................................................................' . . . Radiation.............................................................................................................................. 3-3 3-3 3-3 3-3 HEAT AND TEMPERATURE . . . .......................................................................... 3-4 MAINTAINING THE HEAT BALANCE............................................................................. 3-4 People.................................................................................................................................. 3-4 Houses.................................................................................................................................. 3-5 m FUNDAMENTALS OF ELECTRICITY.................................................................................... 4-1 BASIC ELECTRICAL RELATIONSHIP............................................................................. The Volt.............................................................................................................................. The Ampere....................................................................................................................... The Ohm.............................................................................................................................. The Watt.............................................................................................................................. OHM'S LAW.............................................................................................................................. WATT'S LAW........................................................................................................................... CURRENT, VOLTAGE, AND POWER IN A PARALLEL CIRCUIT........................ RESISTANCE IN PARALLEL CIRCUITS.......................................................................... 4-1 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-3 iii &B029 0493 CHAPTER 4 CHAPTER 5 TABLE OF CONTENTS (Cont) FUNDAMENTALS OF ELECTRICITY (Cont) SERIES CIRCUIT............................................. POWER DISTRIBUTION ............................... Electrical Power Supply ......................... THERMALUX ELECTRICAL PROPERTIES THERMALUX BRANCH CIRCUIT .............. THERMALUX CONTROL CIRCUIT.............. ELECTRICAL CODE REQUIREMENTS . . Electric Power Supply............................... Service Drop.......................................... Underground Service............................ Service Entrance ............................... Service Equipment............................... Load Demand.......................................... THERMALUX Electrical Circuits . . . . Control Circuits................................... Branch Circuits...................................... THERMALUX Heating Panels . . . . Page 4-3 4-4 4-4 4-6 4-6 4-7 4-7 4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-9 4-9 4-9 THERMALUX SYSTEM DESIGN............................................................................................... 5-1 HEAT LOSS.............................................................................................................................. Transmission Heat Loss.................................................................................................. Infiltration Heat Loss..................................................................................................... HEAT TRANSFER ................................................................................................................ Overall Coefficients of Heat Transmission............................................................... HEAT ENERGY EQUIVALENTS........................................................................................ INSULATION.......................................................................................................................... All Weather Comfort Standard .................................................................................... Determining the Required Insulation.......................................................................... Specifing Insulation......................................................................................................... HEAT TRANSMISSION OF WINDOWS AND DOORS ..................................................... Windows............................................................................................................ ... Skylights.............................................................................................................................. Hollow Glass Block......................................................................................................... Doors ................................................................................................................................. TEMPERATURE DIFFERENCE........................................................................................ Calculating Temperature Differences.......................................................................... Inside Design Temperature........................................................................................... Outside Design Temperature........................................................................................ FINDING TRANSMISSION HEAT LOSS............................................................................. Temperature Difference (TD)........................................................................................ Floor and Ceiling Area.................................................................................................. Window Area....................................................................................................................... Floor Slab Heat Loss...................................................................................................... Basement Heat Loss ...................................................................................................... Indoor Temperature Differences................................................................................. FINDING INFILTRATION HEAT LOSS............................................................................. Room Air Changes............................................................................................................. FINDING TOTAL HEAT LOSS........................................................................................... SHORT-CUT METHODS OF FINDING HEAT LOSS........................................................ The Area Calculator......................................................................................................... The Volume Calculator.................................................................................................. Use of Heat Loss Charts ............................................................................................... ACCURACY OF CHARTS...................................................................................................... 5-1 5-1 5-1 5-2 5-3 5-3 5-4 5-4 5-4 5-4 5-5 5-5 5-5 5-5 5-5 5-6 5-6 5-6 5-6 5-6 5-7 5-7 5-7 5-7 5-7 5-7 5-8 5-8 5-9 5-9 5-9 5-9 5-10 5-10 IV ^ 0 2 9 0494 CHAPTER 5 CHAPTER 6 TABLE OF CONTENTS (Cont) THERMALUX SYSTEM DESIGN (Cont) Page ANNUAL ENERGY CONSUMPTION ................................................................................. Degree Days........................................................................................................................ Annual Consumption Formulas..................................................................................... ANNUAL H EATING COST...................................................................................................... DESIGNING THE THERMALUX SYSTEM ....................................................................... Ceiling Irregularities...................................................................................................... Parallel or Perpendicular Installation....................................................................... Wiring Recesses................................................................................................................. ELECTRICAL DESIGN.......................................................................................................... Determining Room Current............................................................................................ Determining Size of Branch Circuit Wiring................................................................ Choice of 2-Wire or 3-Wire Circuits.......................................................................... Overload Protection.......................................................................................................... Locating Junction Boxes................................................................................................... Control Relays.................................................................................................................... Panel Feeders.................................................................................................................... Thermostat Location.......................................................................................................... Service Drop........................................................................................................................ 5-10 5-10 5-10 5-11 5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-15 THERMALUX SYSTEM INSTALLATION.................................................................................... 6-1 NECESSARY CONSTRUCTION KNOWLEDGE.................................................................. 6-1 MATERIALS REQUIRED FOR INSTALLATION............................................................... 6-1 TOOLS REQUIRED FOR INSTALLATION......................................................................... 6-1 ELECTRICAL INSTALLATION............................................................................................... Power Supply ....................................................................................................................... Control Circuits.................................................................................................................... Branch Circuits and Junction Boxes................................................................................ 6-1 6-1 6-2 6-4 SUPPLEMENTARY THERMALUX PANEL FRAMING.................................................... 6-4 WIRING RECESS CONSTRUCTION..................................................................................... 6-4 WIRING RECESS CONSTRUCTION FOR HEATING PANELS PERPENDICULAR TO JOISTS........................................................................................ 1/2" Deep Wiring Recess Construction...................................................................... 1/2" Deep Wiring Recess Construction...................................................................... 1/2" Deep Wiring Recess Construction...................................................................... 1/4" Deep Wiring Recess Construction...................................................................... 6-4 6-4 6-4 6-6 6-6 WIRING RECESS CONSTRUCTION FOR PANELS PARALLEL TO JOISTS .... 6-6 1/2" Deep Wiring Recess Construction...................................................................... 6-6 1/2" Deep Wiring Recess Construction...................................................................... 6-7 1/4" Deep Wiring Recess Construction...................................................................... 6-7 Wiring Recess Construction when Abutting a Wall.................................................... 6-7 Wiring Recess Closing Blocks .........................................................................................^6-8 Wiring Recess Configuration........................................................................................... 6-8 HEATING PANEL INSTALLATION....................................................................................... 6-8 Nailing.................................................................................................................................. 6-8 Cutting Heating Panels to Length................................................................................. 6-8 Cutting Heating Panels to an Irregular Length........................................................ 6-9 Cutting Heating Panels to Width.................................................................................... 6-9 Accommodating Light Fixture Junction Boxes and Other Devices in Heating Panel Areas...................................................................................................... 6-9 Heating Panel Isolation................................................................................................... 6-10 Heating Panel-to-Wall Isolation............................................................................. 6-10 Heating Panel External Corner Isolation............................................................... 6-10 Heating Panel Erection..................................................................................................... 6-11 Filler Panel Erection...................................................................................................... 6-11 V oSw K) VD O VD CHAPTER 6 CHAPTER 7 TABLE OF CONTENTS (Cont) Page THERMALUX SYSTEM INSTALLATION (Cont) FEEDER WIRING INSTALLATION................................................................................ HEATING SYSTEM TESTING AND INSPECTION........................................................ Branch Circuit Resistance Tests............................................................................ Continuous Operating Test.......................................................................................... Inspection...................................................................................................................... Insulation Resistance Tests....................................................................................... Final Inspection........................................................................................................... EXHAUST FAN AND HUMIDISTAT INSTALLATION................................................. FINISH PANEL INSTALLATION................................................................................... Proper Lamination Methods ................................................................................... Adhesive Drying Time Important............................................................................ Adhesion......................................................................................................................... SPECIAL PRECAUTIONS................................................................................................. FINISHING THE JOB........................................................................................................ Painting the THERMALUX Ceiling......................................................................... 6-12 6-16 6-16 6-16 6-17 6-17 6-17 6-17 6-17 6-17 6-18 6-19 6-20 6-20 6-20 REFERENCE DATA............................................................................................................... 7-1 Table 5-1 Table 5-2 Table 5-3 Table 5-4 Table 5-5 Table 5-6 Table 5-7 Table 5-8 Table 5-9 Table 7-1 Table 7-2 Table 7-3 Table 7-4 Table 7-5 Table 7-6 Table 7-7 Table 7-8 Table 7-9 Table 7-10 Table 7-11 Table 7-12 Table 7-13 Table 7-14 LIST OF TABLES Page All Weather Comfort Standards............................................................................................... W of Vertical Glass Sheets (watts per square foot)............................................................ Application Factors for Windows........................................................................................... W of Horizontal Glass Sheets (watts per square foot)........................................................ W of Wall Sections of Hollow Glass Block (watts per square foot)................................ W of Solid Wood Doors (watts per square foot)................................................................... Floor Slab Heat Loss ................................................................................................................ Room Air Changes Per Hour...................................................................................................... Heating Branch Circuit Capacities........................................................................................... Climatic Data - U.S. Cities..................................................................................................... Thermal Properties of Building Materials.......................................................................... Electrical Characteristics of THERMALUX Heating Panel.............................................. Heat Loss Calculation Formulas................................... Electrical Formulas.................................................................................................................... Room Air Changes Per Hour...................................................................................................... W of Horizontal Glass Sheets (watts per square foot)........................................................ W of Vertical Glass Sheets (watts per square foot)............................................................ All Weather Comfort Standards............................................................................................... W of Hollow Glass Block (watts per square foot)............................................................... Floor Slab Heat Loss ................................................................................................................ Heating Branch Circuit Capacities........................................................................................... W of Solid Wood Doors (watts per square foot)................................................................... Application Factors for Windows........................................................................................... 5-4 5-5 5-5 5-5 5-5 5-5 5-7 5-8 5-13 7-1 7-6 7-13 7-14 7-14 7-14 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 BB029 0496 vi Figure 1-1 Figure 2-1 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 3-10 Figure 3-11 Figure 3-12 Figure 3-13 Figure 3-14 Figure 3-15 Figure 3-16 Figure 3-17 Figure 3-18 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 Figure 6-10 Figure 6-11 Figure 6-12 Figure 6-13 Figure 6-14 LIST OF ILLUSTRATIONS Page The THERMALUX Electric Radiant Heating System......................................................... A Typical THERMALUX Electric Radiant Heating System Installation.......................... Electrical-to-Mechanical Energy Conversion........................................................................ Mechanical-to-Electrical Energy Conversion....................................................................... Inefficiency of Energy Conversion in an Automobile......................................................... Example of Mechanical Energy Transfer............................................................................... Radiation Energy Transfer.......................................................................................................... Chemical-to-Heat and Electrical-to-Heat Energy Conversion........................................ Heat Transfer by Conduction ................................................................................................... Heat Transfer by Convection ................................................................................................... Heat Transfer by Radiation....................................................................................................... Emission of Radiant Heat by the Human Body....................................................................... Heat Measuring Instruments....................................................................................................... Transfer of Body Heat................................................................................................................. Clothing Controls Body Heat Loss............................................................................................ Unbalanced Room Heat................................................................................................................. Heating With a Fireplace.............................................................................................................. Heating With Radiators................................................................................................................. Heating With a Forced Warm Air System.............................................................................. Heating With the THERMALUX Electric Radiant Heating System.................................... Cutaway View of THERMALUX Heating Panels.................................................................... Parallel Circuit............................................................................................................................ Practical Parallel Circuit of THERMALUX HeatingPanels............................................. Impractical Series Circuit of THERMALUX HeatingPanels............................................. Equivalent Connections to the Same Loads By 2-Wire and 3-Wire Methods............... Power Distribution System for a Building ........................................................................... Basic THERMALUX Branch Circuit......................................................................................... - Low-Voltage Thermostat Circuit........................................................................................... Acceptable Methods of THERMALUX Branch-Circuit Wiring........................................... Transmission Heat Losses through Building Materials...................................................... Heat Loss by Cold Air Infiltration ......................................................................................... Calculating Resistance (R) from Conductivity (k) and Conductance (C)......................... Calculating Rx for a Wall Section.................................................................................... Calculating Rx and U (or W) for a Wall Section.................................................................... Determining Amount of Insulation Required.......................................................................... Finding Transmission Heat Loss............................................................................................ Examples of Edge Insulation Around Floor Slabs................................................................ Typical Basement Wall Section............................................................................................... Design Temperature Differences............................................................................................ Using the Area Calculator.......................................................................................................... Using the Volume Calculator...................................................................................................... Using THERMALUX Heat Loss Calculator............................................................................ Using THERMALUX Heating Cost Calculator....................................................................... Heating Panel Layout ................................................................................................................. Light Fixture Junction Boxes Adjacent to Heating Panels.................................................. Clearances Required by Typical Cutouts in a Heating Panel........................................... Heating Circuit Loads and Sizes ............................................................................................ Thermostat Location ................................................................................................................. Installing the Power Supply...................................................................................................... Typical THERMALUX Wiring Systems................................................................................. Type 705 Control Relay............................................................................................................. Type 706 Control Relay with Two ControlSystems............................................................... Type 706 Control Relay with One Control System ............................................................... Typical Attic, Wall, and Floor Junction Box Installations.............................................. Wiring Recess Construction (1/2" Depth)............................................................................... Wiring Recess Construction (1/2" Depth)............................................................................... Wiring Recess Construction (1/2" Depth)............................................................................... Wiring Recess Construction (1/4" Depth)............................................................................... Wiring Recess Construction (1/2" Depth)............................................................................... Wiring Recess Construction (1/2" Depth)............................................................................... Wiring Recess Construction (1/4" Depth)............................................................................... Irregular Wiring Recess Construction ................................................................................. x 2-3 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-3 3-4 3-4 3-4 3-5 3-5 3-5 3-6 3-6 3-6 3-7 4-1 4-2 4-3 4-4 4-4 4-5 4-6 4-7 4-8 5-1 5-1 5-2 5-3 5-3 5-4 5-6 5-7 5-8 5-8 5-9 5-9 5-10 5-11 5-12 5-12 5-13 5-14 5-15 6-1 6-2 6-3 6-3 6-3 6-5 6-5 6-5 6-6 6-6 6-7 6-7 6-7 6-8 vii BB029 0497 Figure 6-15 Figure 6-16 Figure 6-17 Figure 6-18 Figure 6-19 Figure 6-20 Figure 6-21 Figure 6-22 Figure 6-23 Figure 6-24 Figure 6-25 Figure 6-26 Figure 6-27 Figure 6-28 Figure 6-29 Figure 6-30 Figure 6-31 Figure 6-32 Figure 6-33 Figure 6-34 Figure 6-35 Figure 6-36 Figure 6-37 Figure 6-38 Figure 6-39 Figure 6-40 Figure 6-41 Figure 6-42 Figure 6-43 Figure 6-44 Figure 6-45 Figure 6-46 Figure 6-47 Figure 6-48 Figure 6-49 Figure 6-50 Figure 6-51 Figure 7-1 Figure 7-2 Figure 7-3 LIST OF ILLUSTRATIONS (Cont) Page Cutting Heating Panel by Scoring through Electrodes and Heating Element................... 6-8 Snapping Heating Panel on Scored Mark................................................................................. 6-9 Cutting Heating Panel with Irregular Shaped End to Length............................................... 6-9 Light Fixture Junction Boxes Adjacent to Heating Panels.................................................. 6-9 Typical Cutouts Made in a Heating Panel......................................................................................6-10 Typical Cross-Bracing for a Heating Panel Cutout.................................................................6-11 Isolating Heating Panel which Abuts a Wall...............................................................................6-11 Isolating Heating Panel which Becomes Part of an External Corner.............................. 6-11 Installing Heating Panels............................................................................................................. 6-11 Cutting Filler Panel Plugs for Heating Panel............................................................................6-12 Wiring Recess Entry Methods....................................................................................................... 6-12 Drilling Wiring Recess for THERMALUX Bushing.....................................................................6-12 Attachment of THERMALUX Bushing......................................................................................... 6-13 Slitting Face Paper to Free Electrode Strip.......................................................................... 6-13 Peeling Back Paper Containing Electrode Strip.................................................................... 6-13 Attaching Electrode Connector Clip to Electrode Strip...................................................... 6-14 Pressing Connector Clip Points Through Electrode Strip.................................................. 6-14 Bending Over Points for Permanent Hold.............................................................................. 6-14 Inserting Feeder Conductor Into Electrode Connector......................................................... 6-14 Clamping Conductor Into Clip for Permanent Contact..............................................................6-14 Stapling Conductor to Wiring Recess.............................................................................................6-15 Typical Conductor Connections.......................................................................................................6-15 Testing Branch Circuit Resistance............................................................................................ 6-16 Typical Exhaust Fan/Humidistat Installation.................. 6-17 Providing Ventilation before Working with Adhesive..............................................................6-18 Rolling THERMALUX AdhesiveOnto Finish Panels.................................................................6-18 Rolling Adhesive Onto Installed Heating Panels................................................................... 6-18 Testing Dryness of Adhesive...................................................................................................... 6-19 Laminating a Panel with Contact Adhesive...................................................................... 6-19 Smoothing Panel Into Preliminary Lamination........................................................................... 6-19 Impacting Face Panels for Positive Lamination........................................................................6-19 Pressure Rolling for Complete Lamination...............................................................................6-20 Incising a Damaged Finish Panel Edge . ................................................................................. 6-20 Joint Taping Finish Panel................................... 6-21 Finishing Corner............................................................................................................................... 6-21 Topping Joint in Finish Panel.......................................................................................................6-21 The Greatest Name in Electric Heat............................................................................................ 6-21 Normal Number of Degree-Days per Year............................................................................. 7-4 Isotherms of Winter Outdoor Design Temperatures............................................................ 7-5 Heat Output of Panels Versus Voltage Input.............................................................................. 7-13 BBO29 O to CD viii ELECTRODE CONNECTORS FILLER PANEL THERMAL INSULATION BB029 0499 Figure 1-1. The THERMALUX Electric Radiant Heating System x CHAPTER 1 THERMALUX - AN IMPORTANT ADVANCE IN ELECTRIC HEATING To meet the increasing demand and need for a highly efficient and economical electric heating system, United States Gypsum has developed and perfected THERMALUX Electric Radiant Heating. The THERMALUX System marks the coming-of-age of electric heating. Revolutionary, but simple, THERMALUX enhances the inherent advantages of electric heating and combines them with new flexi bility of design, ease of installation, and economy of operation. With the THERMALUX System, United States Gypsum continues its long record of leadership in developing ever-better products and systems for the building industry. An integral member of the United States Gypsum product family, the THERMALUX Electric Heating System has all the family characteristics of quality, safety, durability, efficiency, and economy. Safety The unusually low operating temperature of THER MALUX, and the incombustible, electrically non conducting gypsum panels throughout the system, provide outstanding safety. Being flameless, the system eliminates the potential fire, explosion, and air contamination hazards inherent in combustion heating plants. THERMALUX also does away with hot elements and high-temperature operation. The THERMALUX Electric Heating System is ap proved by Underwriters Laboratories, conforms with the National Electrical Code, and meets Federal Housing Administration standards. Comfort The low-temperature, even-radiation of warmth from broad ceiling areas to all parts of the room provides exceptional comfort. There is no forced air move ment to create uncomfortably hot or drafty areas. The air retains its natural freshness and does not be come hot and dry. Each room contains its own "heat ing system" and thermostat. The warmth level most suitable to the occupants and activities can be selected without affecting the comfort level of other rooms. Cleanliness Heat is produced by direct conversion of electric en ergy. There is no smoke, soot, or fumes to soil drapes, furniture, or walls. Heat distribution is by radiation. There are no strong air currents to spread dust and dirt over the room. Cleaning and re decorating are reduced to a minimum. Economy Since the THERMALUX Electric Heating System also is the ceiling, it can be installed with minimum labor and material. Panels can be cut to the exact length needed, and no large stock of varied lengths has to be kept on hand to meet different requirements. Op eration is efficient and economical because the entire panel heating surface is a uniform, low temperature that minimizes heat loss. Convenience No periodic maintenance, lubrication, parts replace ment, servicing, or system cleaning is required. There are no moving parts. Since the heating sys tem is an integral part of the ceiling, there is com plete freedom of architectural design and interior decoration. Furniture can be arranged without con cern about blocking heat sources. Space Economy No furnace consumes valuable space in a closet, utility room, or basement. There are no chimneys or ducts to interfere with improvement of the base ment or other areas into useful living space. Quiet Because there are no moving parts, THERMALUX Electric Radiant Heat is as silent as a light bulb. A NEW PRODUCT FOR THOSE IN THE BUILDING TRADE Architects, builders, heating system specialists, and contractors now have available to them this great new U.S.G. product. This Handbook covers design and installation of THERMALUX Heating Systems to assist these businessmen in capitalizing on the THERMALUX System. 1-1 OCSO tvj vo o on oo CHAPTER 2 THERMALUX SYSTEM COMPONENTS U.S.G. - ONE SOURCE FOR A COMPLETE SYSTEM United States Gypsum, originator of the THER MALUX Electric Radiant Heating System, produces all of the materials necessary to install a complete system other than the controls and those standard electrical components enumerated under Comple mentary Products in this Chapter. However, all of the electrical controls used in the system are de signed to meet rigid U. S. G. requirements. A full description of each THERMALUX System component follows. Heating Panels THERMALUX Heating Panels consist of an electrical resistor (heating element) on an inert, incombustible gypsum base. The resistor extends over the entire panel and contains two copper electrodes for con nection to an electric power source. THERMALUX Heating Panels are designed for 120 Volt AC-DC op eration. At the design voltage, current input is nom inally 0.125 ampere per square foot, and power input is 15 watts for each square foot of area installed, or approximately 50 Btu/hr./sq.ft. Operating temper ature is 115 Fahrenheit or lower. Heating panels must be electrically connected in parallel to standard heating branch circuits. The panels are controlled by special THERMALUX low-voltage thermostats and transformer relays. according to heating requirements, room configura tion, and desirable location, panels can be cut to the exact length when necessary. Cutouts may be made in the panels for installation of lighting fixtures and other ceiling appliances. Filler Panels THERMALUX Filler Panel is installed as a base layer in ceiling areas where heating panels are not required and is used in wiring recess construction. These are 1/2 in. thick, electrically non-conducting, incombustible gypsum panels. Finishing Panels THERMALUX Finishing Panels, specially designed 1/4 in. high-density gypsum panels, are used as the surface layer of the ceiling. Finishing Panels have excellent heat transmission and radiation character- THERMALUX Heating Panels are manufactured 1/2 in. thick, 4 ft. wide, and in various lengths up to 12 ft. The Heating Panels are available in two types -- with heating element over the entire area (A-6048.48), and with heating element on just one-half the area (A-30-24.48). Selected by length and width 2-1 r Insulated Nails Insulated nails, specially developed for the THERMALUX Heating System, are used to attach the Heating Panels to wood ceiling framing. A nylon sleeve insulates these annular ring nails from the electrical resistor, elim inating shock hazard from any misdriven nails. The nails drive easily, are designed so correct usage is obvious, and are readily visible to electrical inspec tors. Branch Circuit Bushings Branch circuit bushings serve as the wiring re cess entrance for branch circuit conductors supply ing power to the THER MALUX Heating Panels. The specially designed bushing accommodates all standard types of branch circuit race way/wiring systems. The use of these bush ings meets the require ments of the National Electrical Code and sim plifies installation. Electrode Connectors Electrode connectors are used to connect branch cir cuit conductors to installed THERMALUX Heating Panels. The connectors are first secured to branch circuit conductors with a pressure-type connection. Then the connector is positively connected to copper electrodes in the THERMALUX heating element. The connector-electrode connection utilizes the proven method of electrical contacting with multiple points which pierce insulation and electrodes. Controls Controls are low-voltage thermostats and trans former/relays which provide room-by-room control to maintain each room at the desired tem perature level. The THERMALUX thermo stats and transformer/ relays have been special ly designed to provide optimum comfort with the THERMALUX System. The controls are very sensitive, and give quick system response to tem perature changes and heat demand. The THERMALUX Humidistat, to automatically con trol operation of an exhaust fan, is recommended to maintain humidity at a desireable level. THERMALUX Adhesive THERMALUX Contact Adhe sive, for on-the-job lamina T'HERmM-UX ) O. tion of Finishing Panels, is specially formulated for use in a THERMALUX Electric *ME6fV* Heating System. It is easy and quick to use and provides a strong bond of the ceiling Finishing Panels to the Heating and Filler Panels without the use of nails or other fasteners. THERMALUX Joint Finishing Materials A smooth, monolithic ceiling surface is created when the THERMALUX System is finished with readymixed PERF-A-TAPE Compound (THERMALUXformula) and PERF-A-TAPE Reinforcement Tape. Then the ceiling can be decorated with any conven tional water-thinned or oil-based paints. BB029 0502 2-2 Complementary Products Complementary products are United States Gypsum THERMAFIBER mineral wool insulation in batt or nodular form, and standard electrical raceways, wiring, cabling, service boxes, circuit breakers, and junction boxes. THERMALUX SYSTEM DESIGN To assure maximum comport and efficiency, each THERMALUX System is custom designed to meet the specific needs of the building and its occupants. Heat loss is calculated for each room in accordance with the recommendations of the American Society of Heating, Refrigerating, and Air Conditionion Engineers. The THERMALUX Heat Loss Calculators simplify design work on standard types of construction. Heat ing Panel layout is then worked out for each room on the basis of the heat loss calculations, room config uration, and comfort requirements. Electrical bianch circuit design for best load balance, safety, and economy completes the plan. After the system is installed, it is tested and inspected to insure opti mum performance. A typical THERMALUX instal lation is illustrated in Figure 2-1. THERM-MUX THERMALUX WIRING FINISHING PANEL THERMALUX ELECTRODE CONNECTOR Figure 2-1. A Typical THERMALUX Electric Radiant Heating System Installation 2-3 C3 O uro; o ui ou> CHAPTER 3 HEAT SOURCE FUNDAMENTALS ENERGY Heat is a form of energy, as are electricity, light, mechanical energy, chemical energy, and atomic energy. If something is able to do work, it is said to possess energy. For example, a man can do work and so he possesses energy; a mixture of gasoline and air possesses energy since, when it is ignited, it is able to push the piston within the cylinder of an automobile engine; the spring of a screen door pos sesses energy since, when the door is opened, it is able to close the door. Energy exists in many different forms. For ex ample, coal has chemical energy, a streched spring has mechanical energy, a charged capacitor has electrical energy, and a hot substance has heat en ergy. The amount of energy which something possesses is equal to the amount of work it can do. Thus, if a heavy object can do 500 foot-pounds of work in fall ing, it had 500 foot-pounds of energy before it fell. Work and energy are essentially the same kind of quantity and expressed in the same units. Figure 3-1. Electrical-to-Mechanical Energy Conversion Power In practically all cases where work is done, both the amount of work and the time during which the work is done are important. This "time rate of doing work" is called power and may be expressed as Power = Amount of Work Time Interval For example, electrical energy can do the work of turning a motor. The rate at which the electricity is used in turning the motor is the power involved. ENERGY CONVERSION One form of energy can be converted into another. Figure 3-1 indicates that, in turning an electric motor, electrical energy is converted to mechanical energy. At a hydro-electric plant, Figure 3-2, the opposite conversion is made as the mechanical ener gy of the moving water is converted to electricity. Another common type of energy conversion occurs in an automobile engine, where the chemical energy in the fuel is converted to mechanical energy. The process of energy conversion is never 100% effi cient as some energy is always wasted in the pro cess. In an automobile, for example, only a fraction of the chemical energy in the gasoline actually goes into mechanical energy driving the wheels. As in dicated in Figure 3-3, part of the energy of gasoline Figure 3-2. Mechanical-to-Electrical Energy Conversion is wasted because combustion is not complete; part is wasted in heating up the engine block, part of it goes out the exhaust, and part of it is lost in friction (which converts to heat). It is important to realize here that energy is never really "lost" but merely transformed or converted to another type of energy. The energy given up by 3-1 BB029 0504 s of radiation, but there is a definite transfer of ener gy. Radiation, as shown in Figure 3-5, is the means in which we get energy from the sun, the source of all energy on the earth. Figure 3-3. Inefficiency of Energy Conversion in an Automobile a body is imparted to other bodies without loss. Therefore, within any imaginary boundry through which no energy is lost or gained, the total amount of energy remains unchanged. This illustrates a general thermodynamic law known as the "Law of Conservation of Energy." This law states that "energy can neither be created nor destroyed, " and that therefore "the total amount of energy in the uni verse remains constant." TRANSFER OF ENERGY Energy can be transferred, or moved from one point to another, in various ways. The most common way is through some kind of connection, or contact. As in Figure 3-4, when you hit a golf ball with a club, mechanical energy from the club is transferred to the ball at impact and this energy becomes kinetic energy of the ball in motion. Similarly, the mechan ical energy from an automobile engine is transferred to the wheels through a series of gears and other mechanical connections. Electrical energy, also, flows from one point to another through various con ductors and connectors. GENERATION OF HEAT In home heating systems, heat is generated through conversion of either chemical energy or electrical energy -- that is, through the burning of fuel or through the flow of electricity through a resistor, as indicated in Figure 3-6. ELECTRICAL TO HEAT ENERGY CONVERSION CHEMICAL TO HEAT ENERGY CONVERSION Figure 3-6. Chemical-to-Heat and Electrical-toHeat Energy Conversion Figure 3-4. Example of Mechanical Energy Transfer Of the two, the conversion of electricity into heat is far more efficient. In fact, it is the only perfect energy conversion man can make because there are no intermediate steps -- it is a direct conversion. There are no moving parts to cause friction and no fuel combustion to be incomplete. Another, and completely different, method of trans ferring energy is by means of radiation. There is no contact or connection whatsoever, from the source When fuel oil is burned to produce heat, the conver sion is approximately 60% efficient. The conversion tn of gas to usable heat is at an efficiency of approxi- 3-2 mately 67%. However, the direct conversion of electrical energy to heat is 100% efficient. Because of its efficiency, electricity is frequently called the "perfect" fuel. Of course, if the entire conversion process of elec tricity to heat were considered on the basis that electricity is derived from the chemical energy of the burning of coal or the mechanical energy of mov ing water, the conversion efficiency would be less than 100%. However, in practical terms, the effi ciency of electric heating must be based on the "electrical fuel" consumed. HOW HEAT IS TRANSFERRED Heat travels in three ways -- by conduction, convec tion, and radiation. It may travel by one, two, or all of these methods at the same time. Conduction Conduction of heat is its transfer through physical matter. When one end of a metal rod is heated, as in Figure 3-7, the other end becomes hot because the heat is conducted through the rod. Similarly, when the heated rod is held against another object, that object becomes hot because of conduction. duction. The kettle is heated by conduction. Then the kettle conducts heat to the water in contact with it. The heated water decreases in density (becomes lighter) and moves upward to provide heat transfer by convection. Radiation Radiation of heat is heat transfer through space by rays or waves. The sun radiates electromagnetic energy. That is, the sun sends out rays, or waves, which travel through space and bring energy of var ious kinds to the earth and other planets. This ra diant energy covers a complete range, or spectrum, of closely related kinds of energy. Some of it is visible light, some of it infra-red and ultra-violet, some heat, some cosmic rays, some X-rays, and so on. Radiant heat, like light, travels in straight lines. Like light, it is transmitted almost instantaneously. The waves from the sun go out in all directions and continue in a straight line until they hit some object which obstructs them. Then the energy waves are either absorbed by the object or reflected from it in a straight line. The most important characteristic of radiant energy from the sun is that it transfers heat many millions of miles without any kind of con tact or connection. Convection Convection is the transfer of heat by actual move ment of the heated material and applies to liquids and gasses. Motion of the material is caused by density changes that accompany the heating process. An interesting fact to remember is that heat transfer by convection cannot occur alone. Convection must always be preceded by another heat transfer process such as conduction. For example, water in a tea kettle, Figure 3-8, is heated by convection and con Radiant heat does not appreciably warm the air through which it passes. Only the objects which receive radiant energy get warm. This is well ex emplified by the heat we get from the sun, Figure 3-9, which can melt snow even when the air temper ature is very cold. The atmosphere away from the earth is very cold because there is nothing solid for the radiant heat from the sun to warm. Near the earth, however, the air is heated because of the water vapor and dust particles (solids) which par tially absorb radiant energy. 3-3 BB029 0506 As a matter of convenience, heat units are based on the change of temperature of definite quantities of water. The quantity of heat required to produce a given rise of temperature is directly proportional to the amount of water heated and may be expressed as: QUANTITY OF HEAT (BTU) = UNIT OF WATER x TEMPERATURE CHANGE Thus, it would take twice as much heat to raise a given amount of water through, say 100 degrees than it would through 50 degrees. The unit generally used for measuring heat produc tion or heat loss is the British Thermal Unit, or Btu. A Btu is defined as the amount of heat required to raise the temperature of one pound of water, at 60 Fahrenheit, one degree Fahrenheit. Figure 3-9. Heat Transfer by Radiation On earth, too, heat is transferred by radiation. As shown in Figure 3-10, we get heat from a campfire by radiation. The human body is also a source of heat which can be emitted or radiated. Terms such as cold, cool, warm, and hot are com mon in everyday speech to indicate the temperature of something. But, these terms are not specific enough and have led to the adoption of certain ther mometric scales, Figure 3-11. These scales are set up using two standard, easily reproduced, tem peratures. The reference temperatures chosen are the melting point of ice and the boiling point of water, both at standard atmospheric pressure of 76 centi meters (29.92 inches) of mercury. WATER BOILS 212 200 190 180 170 160 150 130 110 140 180 DEGREE 120 DIVISIONS 100 r 100 h 90 80 70 60 100 DEGREE 50 DIVISIONS 40 90 80 30 70 60 r 20 ICE MELTS.*. OR FREEZES] 50 40 32 20 10 0 - 10 - 0 I- 10 L 20 OO FAHRENHEIT CENTIGRADE THERMOMETER THERMOMETER Figure 3-11. Heat Measuring Instruments Figure 3-10. Emission of Radiant Heat by The Human Body The most important temperature systems are the Fahrenheit scale, which establishes 212F as the boiling point of water and 32F as the melting point of ice, and the Centigrade scale, which has a 0C melting point and 100C as the boiling point. MAINTAINING THE HEAT BALANCE HEAT AND TEMPERATURE Heat is a form of energy. When heat is applied to an object it raises the energy level and causes an in crease in "temperature." Temperature is a term used to express how cold or how hot an object is; cold implies a low temperature and hot a high tem perature. People Human beings are heat-producing machines. We ^ convert food energy by a metabolic process into ^ heat energy. Even when we're idle, our "motors" to are running and are producing heat. To stay com- 0 fortable (and alive) we have to continuously throw ^ off body heat. - 3-4 Normally, this is easy. As shown in Figure 3-12, 400 Btu per hour -- 100 Btu by evaporation, 150 Btu I our bodies are at about 98.6F, the temperature by convection, and 150 Btu by radiation. around us is at about 70F. Since heat always travels from points of higher temperature to points Just having the right air temperature in a room is of lower temperature, the body can lose heat and not enough to assure us of comfort if the room heat presumably be comfortable. is not properly balanced. For example, Figure 3-14 illustrates a room which has a source of heat on one side and a big picture window on the other. Let's assume that the room has a heat source hot enough to bring the air temperature in the room to an average 70F. A person near the picture window can be extremely uncomfortable because of convec tive heat loss to the cooler air and radiant heat loss to the window. Another person, close to the heat source, in the direct path of the heat, can be too hot. As measured by a thermometer, the room is warm enough. As measured by human comfort, it is poorly heated and uncomfortable because of the heat imbalance. Having balanced heat in a house is almost as important as having enough heat. When the temperature about us gets too cold, how ever, our bodies throw off heat too rapidly, and we become uncomfortable. That's why we need heating systems for our homes in winter -- not to heat our bodies, but to keep them from losing heat too rapid ly. The proper clothing (Figure 3-13) is also vital to control heat loss from our bodies -- not too fast -- and not too slow -- if comfort is the goal. Figure 3-14. Unbalanced Room Heat Houses In winter, heated buildings are always losing heat to the atmosphere. To maintain comfort, heating sys tems must produce just the right amount of heat in the right places to keep the balance of heat input equal to heat loss. Creating and controlling a com fortable environment has not been easy, and man has been experimenting for a long time to find the answer. With fires, fireplaces, and stoves, of course, a person was too hot near the fire and too cold away from it; besides, it took a great deal of work to keep a fire going in each room. Figure 3-13. Clothing Controls Body Heat Loss Our bodies lose heat by radiation as well as by con vection and evaporation. In fact, an average adult under comfortable indoor conditions will lose about Heat radiating from a fireplace, as shown in Figure 3-15, heats walls and contents of a room unevenly. Air, contacting room surfaces, becomes heated by ,, conduction, then circulates by convection to trans- 63 fer heat throughout the room. ID 3-5 O U1 O 00 Air, heated in a furnace, is circulated by a blower to distribute heat by convection. When the warm air contacts walls, windows, and contents of the room, it heats by conduction. Heat transfer by radiation does not occur in such heating systems. Figure 3-15. Heating With a Fireplace The advent of central heating systems eliminated the need for many fireplaces (or pot-bellied stoves), and reduced the burning of fuel to a furnace in just one location. Now, heat could be generated by burning coal, oil, or gas, and transferred with steam, hot water, and warm air. Results obtained are indicated in Figures 3-16 and 3-17. - Figure 3-17. Heating With a Forced Warm Air System The thermostat further improved comfort by provid ing semi-automatic heat control. This system is based mainly on the constant availability of fuel, with its feed controlled by a single thermostat. Com fort is fairly constant in the general area of the thermostat. Away from it, though, in other parts of the house, maintaining the right temperature is still a real problem with most heating systems. With all the advances that have been made in heating systems, the problem is still the old one of how to add just the right amount of heat in each room and distribute it so that every part of the room is com fortable . THERMALUX Electric Heating solves that problem most effectively. THERMALUX Electric Heating provides a thermostat in every room. Therefore each room can be automatically maintained at the temperature most suitable to its occupants and ac tivities, without regard to the comfort level selected for adjacent rooms. Figure 3-16. Heating With Radiators Air, by a steam or hot water radiator, is heated by conduction. The warm air expands and rises, trans ferring heat by convection. As the air circulates, it transfers heat by conduction to walls, windows, and contents of the room and becomes cool again. Heat transfer also occurs by direct radiation from the hot radiator. Because THERMALUX Heating Panels heat uniform ly throughout, there are no hot spots. As large-area heat sources, THERMALUX Heating Panels do not concentrate heat in one location and cause wide differ ences of temperature elsewhere. Heat radiates from a THERMALUX ceiling in all directions, as shown in Figure 3-18, like rays of light, reaching and warming every part of the room -- floors, walls furnishings, people. Then, as the walls and floors are warmed, the air next to them are warmed by conduction. This heated air sets up very gentle con vection currents which circulate the warmed air im perceptibly. People are completely comfortable. 3-6 fiB029 0509 i. f 3-7 6? 0g g  CHAPTER 4 FUNDAMENTALS OF ELECTRICITY THERMALUX Electric Heating is based on the prin ciple that electric current flowing through a resistor produces heat. THERMALUX Heating Panels, illus trated in Figure 4-1, are very large, special, elec trical resistors on a gypsum base. The resistor, comprised of a conductive coating and two copper electrodes in an asbestos envelope, functions as a heating element. The gypsum panel serves as an in combustible, electrically non-conductive base for the resistor. When electric power is connected to the Heating Panel electrodes, current flows through the resistor and the entire panel warms uniformly to a temperature of 115F, or lower. BASIC ELECTRICAL RELATIONSHIPS Electric heating is based on the fundamental prin ciples of electricity. The purpose of this chapter is to give the electrical fundamentals that are needed to design a THERMALUX Electric Radiant Heating Sys tem. There are four basic units of electricity. These are: the volt, the ampere (amp), the ohm and the watt. The Volt The volt is the electrical unit of force. Just as water pressure is measured in pounds per square inch, electric pressure is measured in volts. House power is normally either 120 volts or 240 volts. The Ampere The ampere is the electrical unit of flow. Just as water flow is measured in gallons per minute, the flow of electricity (current) is measured in amperes (amps). The Ohm The ohm is the electrical unit of resistance. Just as a water pipe offers resistance to the flow of water, an electrical conductor offers resistance tp the flow of current. When a water pipe is made larger, re sistance decreases and more water will flow through the pipe with the same water pressure applied. When an electrical conductor is made larger, there is less resistance and more current (amps) will flow through the conductor with the same voltage applied. Figure 4-1. Cutaway View of THERMALUX Heating Panels 4-1 The Watt The watt is the unit of electrical power and expresses the amount of energy the electric system is using. OHM'S LAW Ohm's law is the first law of electricity and states that a force of one volt will cause a current of one amp against a resistance of one ohm. Arithmetical ly this is stated as: E = IR E = voltage (volts) I = current (amperes) R = resistance (ohms) The terms of Ohm's law can also be transposed to establish the following relationships: All three formulas say the same thing but in a differ ent form. The formula used depends on what elec trical properties are known and what must be calcu lated. EXAMPLE: How much power is consumed by the 30 ohm resistor, connected to 120 volts and drawing 4 amperes cur rent ? P = El = 120 x 4 = 480 watts P = I R = 4 x 4 x 30 = 16 x 30 = 480 watts ,, E2 120 x 120 14400 ^ p = -R = --30" = IT = 480 watts CURRENT, VOLTAGE, AND POWER IN A PARAL LEL CIRCUIT In the parallel circuit shown in Figure 4-2, resistors Rj, R2, and R3 have their terminals joined together at points X and Y. Current divides at point X with part of it going through Rj, part through R2, and the remainder through R3. All of the individual currents re-combine at point Y and flow to the positive ter minal of the battery. The voltage across each of the three resistors is equal to the potential difference between points X and Y and is equal to the applied voltage erf the battery. Therefore, the voltage across each resistor is 120 volts (Ej = E2 = E3 = 120v). EXAMPLE: An electrical resistor rated at 30 ohms is connected into a 120 volt circuit. What is the current flow through the resistor? 1 = I = ^ = 4 amPeres WATT'S LAW Figure 4-2. Parallel Circuit Watt's law is the second law of electricity and states that a force of one volt causing a current of one amp uses the power of one watt. Arithmetically this is stated as: P = El P = power (watts) E = voltage (volts) I = current (amps) Since, according to Ohm's law, E = IR, substitution of like quantities in Watt's basic law give the alter nate versions: P = I^R p= (by substituting IR for E) (by substituting yE for R) Again, all three variations of Watt's formula say the same thing in different form, and the choice of for mula depends on what electrical factors are known and what must be determined. To find the total current supplied by the battery to the combination of parallel resistors, first find the current through each individual, resistor, and then find the sum of the individual currents. You can readily find the individual currents by Ohm's law (I = E/R). 1. Current through Rj is T E1 120 ,, c \ =Rp 240 = 0'5 amPere- 2. Current through R2 is T E2 120 ,, Z2 = R^ = W=2 amperes' 3 . Current through R3 is t E3 120 . x3= r; = IF = 4 amperes- fOC&sDj hLO-n> to 4-2 4. The total current, It; is 1^ = 1^ +12+12=0.5+2+4 = 6.5 amperes. The total power expended by the battery is equal to the sum of the power expended in the individual re sistors. This can be found by the power formula, P = El. 1. Power in R] is P1 = E ^ = 120 x 0.5 = 60 watts. 2. Power in R2 is P2 = E2 I2 = 120 x 2 = 240 watts. 3. Power in R 3 is P3 = Eg Ig = 120 x 4 = 480 watts. 4. The total power, pt; is Pt = P1 + P2 + P3 = 60 + 240 + 480 = 780 wattsSince the total current is already known, the total power can also be found by Pt = E It = 120 x 6.5 = 780 watts. Application of the schematic representation shown in Figure 4-2 to THERMALUX Heating Panels gives a practical parallel circuit, as indicated in Figure 4-3. The calculations for Figure 4-2 are still valid here and represent the figures necessary to produce the heat required (P = 15 watts/sq. ft.) with a constant voltage drop of 120 volts across each panel. For example, the power expended in Rj is 60 watts. The area (Aj) of Heating Panel is 4 square feet (see Figure 4-3). Therefore, the power per square foot is: p P^/sq.ft. = = 15 watts/sq.ft. RESISTANCE IN PARALLEL CIRCUITS When the total current is known, the total resistance in a parallel circuit may be found by the Ohm's law formula, R = E/I. Thus, the total resistance in the circuits of Figures 4-2 and 4-3 is: E R^ = = 18.46 ohms. Note that the total resistance of 18.46 is less than any one of the individual resistors Rlt R2, and R3. The resistance of two or more branches in parallel is always less than the resistance of any of the com ponent branches. When resistors are connected in parallel the total resistance is given by the formula: _1___1_ _1_ _1_ 1 vvw -Rn When THERMALUX is connected in parallel the total resistance can also be found by using the short cut formula: Rt = 960/A; where A is the total area of all the Heating Panels in the circuit. To summarize, in a parallel circuit, which is the only way THERMALUX Heating Panels can be con nected, the voltage to each panel is the same (120 volts), while the current to each panel varies accord ing to the panel resistance. Therefore, the current draw and heat output per square foot of panel area are equal and proportional to area of Heating Panel installed. SERIES CIRCUIT . The THERMALUX Heating Panels in the circuit of Figure 4-4 are connected in series. When resis tances are connected in series they are additive. That is: Rt = R; + R2 + R3. Therefore, the total series resistance is 240 + 60 + 30 = 330 ohms. Power is equal to E2/R. Therefore, 120 x 120/330 = 14400/330 = 43. 33 watts; less than the power expend ed by the smallest panel when the panels are connec ted in parallel. Figure 4-3. Practical Parallel Circuit of THERMALUX Heating Panels r This shows that when THERMALUX Heating Panels are connected in series the heat output for the cir cuit is less than the heat output that can be gotten from one panel. NEVER connect THERMALUX Heating Panels in series. A separate overload protector (fuse or circuitbreaker) is provided for each branch circuit. Gen erally, these overload protectors are also contained in the common service box. Each branch circuit breaker is rated to handle the load current of its associated branch circuit. If the load current does not equal a standard breaker rating, the breaker used must have the next higher standard rating. (For example, an 18-ampere load would require a 20ampere breaker.) The service-drop, service-entrance, and main-fuse ratings are determined by the total load demand. "Load demand" is not the sum of all individual load currents, but is based on a "demand factor" which represents the percentage of all loads that are likely to be turned on simultaneously (This may make the main fuse ratings appear somewhat low at first glance.). Figure 4-4. Impractical Series Circuit of THERMALUX Heating Panels POWER DISTRIBUTION Electric Power Supply Electric power is supplied to a building from a utility distribution line (pole) by means of a service drop or underground service, as shown in Figure 4-6. The service drop or underground service is installed by the power company in most localities. The cable or raceway system that brings electric power into the house is called the service entrance. At the service entrance is a power meter which re cords the number of kilowatt hours of electricity used in the house. The service equipment at the service entrance includes grounding and guarding, a means of overcurrent protection, and a main dis connect device. The chief item of service equipment is the service box. It generally includes some type of main dis connect device and some kind of overload protection. The main disconnect device is used to turn off the power for the entire electrical system within the house. This may be a switch or a removable fuse block. A set of main fuses provides overload pro tection for the entire electrical system. The main fuse block may be designed for easy removal; in that case, it serves as the main disconnect device, and no separate disconnect device is required. Within the service box, power is connected for dis tribution through the house by means of branch circuits. One branch circuit, for example, might supply the power for the electric range, several more branch circuits for other appliances and lights in the kitch en, and other branch supplying power for the lights and convenience outlets in other rooms. There are also branch circuits for the THERMALUX Heating Panels in each room. There are two types of branch circuits: 2-wire and 3-wire. The 2-wire branch circuit is used for gen eral purpose loads such as lighting, small appliances and electric heating loads which require relatively little current. Where large amounts of current are required, such as an electric kitchen range or an electric heating system, heavier wire is needed. A 3-wire branch circuit has the advantage of requiring less wire. Therefore, it is less costly than its equivalent using the 2-wire branch circuit method. THERMALUX Heating Panels can be connected in two ways: by a 2-wire branch circuit and by a 3-wire branch circuit. Both methods produce the same re sults within their respective loads (Rt's). Note, in Figure 4-5, however, that two 2-wire branch circuits (4 wires) are required as compared to one 3-wire branch circuit to obtain the same result. 120 VOLTS J__ HOT WIRE NEUTRAL WIRE t ROOM A 120 VOLTS I___ HOT WIRE NEUTRAL WIRE 2-WIRE BRANCH CIRCUITS t ROOM B 240 VOLTS HOTWIRE | 120 VOLTS COMMON NEUTRAL--------WIRE 120 VOLTS HOT WIRE 3-WIRE BRANCH CIRCUIT ROOM A R ROOM B Figure 4-5. Equivalent Connections to the Same Loads By 2-Wire and 3-Wire Methods 4-4 BB029 0514 15 BRANCH CIRCUITS 15 or 20Ampere General Purpose Circuits LAMPS, TV, RADIO CEILING LIGHT FIXTURES Two 20-Ampere KitchenAppliance Ci rcui ts REFRIGERATOR, FOOD MIXER TOASTER, DEEP FRYER, FRY PAN SHAVER, VACUUM CLEANER, HI-FI STEAM IRON, DISHWASHER, RANGE SERVICE BOX THERMALUX CONTROL SWITCHES THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX HEATING PANEL LOAD THERMALUX THERMOSTAT CONTROLS Figure 4-6. Power Distribution System for a Building 4-5 ottoo vfoo o Ln h-> Ln THERMALUX ELECTRICAL PROPERTIES THERMALUX Heating Panels are designed for con nection to 120 volt AC-DC power circuits. When power supply is different than 120 volts, determine variation in heat output from Figure 7-3. The THERMALUX Heating Panels have resistance relationships carefully established at the factory so that current draw and heat output are equal for each square foot of panel area. To determine electrical and heating properties, the 22-inch wide element on A-30-24.48 panel is considered to be 24 inches or fully 2 feet wide. Similarly, for design purposes the 46-inch element on A-60-48.48 is established at 4 feet wide. Current used by THERMALUX Heat Panels is as follows: CURRENT Panels draw 0. 125 amps (1/8 amp) per square foot of element area. The A-30-24.48 panel draws 0.25 amps (1/4 amp) per lineal foot. The A-60-48.48 panel draws 0.50 amps (1/2 amp) per lineal foot. The current used by each type panel is printed on the heating elements. Power used and Heat Output by THERMALUX Heating Panels is as follows: POWER Panels use 15 watts of power and produce 15 watts of heat energy per square foot of element area. The A-30-24.48 panel produces 30 watts of heat per lineal foot. The A-60-48. 48 panel produces 60 watts of heat per lineal foot. EXAMPLE: A standard 12 foot THERMALUX Panel A-30-24.48 must be reduced to an 8 foot length for installation. What is resistance of installed part? Area (installed part) = 8x2 =16 R = -yg- = 60 ohms A 12 foot THERMALUX Panel A-60-48.48 is cut into 4 foot and 8 foot pieces. What is resistance of each piece? Area (4ft.) = 4x4 = 16 r4 ft.= "nr= 60 ohms Area (8 ft.) = 4 x 8 = 32 R8 ft. = ~32" = 30 ohms' THERMALUX BRANCH CIRCUIT Figure 4-7 schematically illustrates the basic THERMALUX circuit. Branch-circuit power is supplied from the service box to a control relay. The relay unit (actually a line voltage switch), is controlled by a low voltage thermostat to connect or disconnect power to Heating Panels. Power is pro vided by a heating branch circuit, through a junction box into panel feeder wires. Radiant heat from the Heating Panels operates the thermostat to complete the control system. The junction box is necessary to permit running panel feeder wires (UF cable) into a gypsum enclosure (wiring recess) where they are connected to the Heating Panel electrodes with THERMALUX Electrode Connectors. The panel feeders enter the wiring recess through a specially designed type of bushing (THERMALUX Bushing). THERMALUX WIRING The power consumption and heat production of each type panel is printed on the heating ele ments. Determine total heat output of a THERMALUX System by multiplying the square foot area of heating panel by 15 watts. Heat capacity can also be calculated from lineal footage of each type panel installed. BB029 0 ^ 6 Actually, from the standpoint of designing and in stalling THERMALUX Heating Systems it is only necessary to know current requirements and heat output of the Panels. However, it is sometimes useful to know the installed resistance of Heating Panels. This can be quickly and simply determined from the following equation: R = R = resistance (ohms) A = area of heating element (square feet) 4-6 SERVICE BOX Figure 4-7. Basic THERMALUX Branch Circuit THERMALUX CONTROL CIRCUIT The thermostat functions as a temperature-sensitive or automatic switch. It turns on the power to the Heating Panels when the room temperature drops below its setting and turns off the power when the room temperature reaches the set value. The THERMALUX system uses low voltage switching for safety, economy and optimum comfort control. Low-voltage switching requires a low-voltage ther mostat and a control relay, as illustrated in Figure 4-7. The thermostat controls the low-voltage relay which in turn controls power to Heating Panels through a line voltage switch. The transformer re duces the line voltage to a low voltage to operate the relay. Two types of control relays are available: a single and a double. The single type has one line voltage switch, as shown in Figure 4-8, which can handle a maximum load current of 22 amperes. The double type has two line voltage switches, each rated for 22 amperes (max.), and can be wired for control by either one or two thermostats. Complete directions for installing THERMALUX Thermostats and Control Relays are available in separate data sheets. ELECTRICAL CODE REQUIREMENTS The electrical code, adopted by each local govern ment is the specification that must be followed for all types of electric wiring and apparatus. Gen erally, local electrical codes are the National Elec trical Code, which is a standard of the National Board of Fire Underwriters. (It is important to realize that the National Electrical Code is only advisory until adopted by a government body. Then it becomes regulatory.) However, some local codes modify or prohibit some practices permitted by the NEC. For example, a local code may adopt the NEC but prohibit the use of knob-and-tube wiring, non-metallic sheathed cable, and armored cable for new work. The sections of the 1962 National Electrical Code which apply to installations of the THERMALUX Electric Radiant Heating System are referenced in this chapter. The following are the general sections 1. The index in the National Electrical Code is a complete alphabetical listing by subject. The NEC has many sections which are inter related but not necessarily cross-indexed. Therefore, it is important to be familiar with the entire code. 2. Article 90 of the National Electrical Code is a short introduction that outlines the pur pose and content of the code. The basic purpose is that of "safety" -- not specifica tion or restriction upon the use of particular products. THERMALUX has been deemed safe by extensive Underwriters Laboratories testing. A U/L listing is given only to pro ducts that can be installed in conformance with NEC requirements. THERMALUX is listed by U/L. 3. Article 100 is a definition of terms and their use. It is important to know the terms to understand the code. CONTROL RELAY HEATING Rt= PANEL LOAD Figure 4-8. Low-Voltage Thermostat Circuit 4-7 to Oto fo O U1 I-1 4. Article 110 describes general wiring methods and procedures. t Electric Power Supply The complete electrical service (service drop, underground service, service entrance, and service equipment) is covered by Article 230 of the National Electrical Code. Service Drop The service drop is covered in Article 230-C. Underground Service This type of service is covered in Article 230-D. Service Entrance The service entrance (conductors, cables, raceways, and fittings) is covered by Articles 230-E and 230-F of the National Electrical Code. The size of service- entrance conductors is determined in accordance with Article 230-41 and the calculations in Article 220. An unusual installation may require feeder conductors and the added consideration of voltage drop as covered by Article 215-3. -- Service Equipment Service equipment is covered by Articles 230-G, 230-H, 230-J, and 230-K. Article 230-G gives gen- eral information. Grounding and guarding is covered by Articles 230-H and 250. Article 230-J covers disconnecting means. Article 230-K and Article 240 cover overcurrent protection. Load Demand The methods of calculating load demand are given in Article 220 of the National Electrical Code. THERMALUX Electrical Circuits By examining the functional block diagram of one THERMALUX branch circuit, as shown in Figure 4-7, one may understand the complete system oper ation since all THERMALUX branch circuits operate in the same basic manner. Branch circuit power is supplied from the circuit breaker or fuse in the ser vice box to the control relay by conventional wiring. Power from the control relay to the junction box is also carried by conventional branch circuits. Up to the junction box, any wiring that meets local code requirements for all other branch circuits is satis factory for THERMALUX branch circuits. Figure 4-9 illustrates some of the types of wiring that may be used. Only the wiring from the junction box to the THER MALUX Heating Panels is a special requirement designed to meet the needs of the THERMALUX Sys tem. Type UF cable (single conductor) is used for this purpose. For clear reference, the wires in this part of the branch circuit (the Type UF cable from junction box to Heating Panel) are called panel feeders in this Handbook. Figure 4-9. Acceptable Methods of THERMALUX Branch-Circuit Wiring 4-8 o co The only other special provision is that panel feeder connections to the Heating Panels must be surrounded on all sides with incombustible electrically nonconductive material when the ceiling is completed. To meet these requirements, the THERMALUX Elec tric Heating System uses wiring recesses in the ceil ing. Ends of Heating or Filler Panels forming the sides of the recess and Filler Panel forms the top and ends of the recess. The wiring recess provides clearance for the panel feeders and their connection to the Heating Panels. The bottom is open so that the wiring can be completed, tested, and inspected. After the electrical installation has been approved, the final layer of Finish Panels is bonded to the Heating Panels. These form the bottom of the wiring recess and complete the enclosed, continuous recess of non-conductive, non-combustible gypsum. From the junction box to the point of its entry into the wiring recess. Type UF cable may be used alone or carried in metal conduit, as specified by the local electrical code. The entry of the Type UF cable into the wiring recess may be through a THERMALUX Bushing, bushed end fitting, or simply through a hole in the gypsum panel. The method used must comply with the local electrical code. Control Circuits THERMALUX control circuits must comply with the requirements for class 2 control circuits as specified in Article 725 of the National Electrical Code. Design and installation are conventional. Branch Circuits Branch circuits are covered in general by Article 210 and 300 of the National Electrical Code. Speci fic types of wiring using non-metallic cable, thin wall conduit (EMT) and flexible metal conduit are covered in Articles 318 through 356 of the National Electrical Code. The size of conductors used is specified by the code (Article 310-12), depending on the amount of current they may have to carry. How ever, if a circuit has to carry current for long peri ods, it is derated by reducing the current-carrying capacity of the conductors. Conductors used in THERMALUX branch circuits and direct Heating Panel connections must be derated 20% in current carrying capacity in conformance with Article 21023(b). This is required since the THERMALUX System may be operating continuously for a number of hours during very cold weather. Branch circuit conductors for THERMALUX Systems conform with Articles 422-42 and 422-47 of the NEC. In most cases, careful system design and installation will avoid the need for derating because of temper ature. By Article 370-19 of the National Electrical Code, junction boxes must be accessible after all construc tion and decorating have been completed, and con nections in the junction box must be available for inspection at any time, by removal of the junction box cover plate. This Code provision applies to the THERMALUX System as the UF cables must be run from the connector clips back to an accessible junc tion box. However, Article 370-19 is not applicable to the electrode connectors made in the field since those connections are accessible for inspection be fore the Finish Panel is applied. THERMALUX Heating Panels Article 422 of the National Electrical Code covers appliances, and many sections of this article apply to THERMALUX Heating Panels, which are con sidered "fixed appliances", in the application of the code. Article 422-E specifically deals with fixed electrical space heating. However, Article 422-43 of the National Electrical Code, which prohibits the cutting of panels and cables, does NOT apply to THERMALUX Heating Panels- This restrictive article was made neces sary by the design of ceiling cable, and other elec tric heating elements, in order to limit their power density and avoid possible danger from elevated op erating temperatures which result from varying manufactured size. Chapter 6 describes the methods in which THERMALUX Heating Panels may be cut. CHAPTER 5 t THERMALUX SYSTEM DESIGN The design of a THERMALUX heating system is based on the same fundamental principles of heat transfer used to plan any high quality heating installation. Gen erally, what must be done is to determine heat loss from the building, then design a THERMALUX System to replace the lost heat wherever and whenever it is needed. HEAT LOSS Heat may be lost from a building in two ways; by transmission heat loss and by infiltration heat loss. Each is described below. Transmission Heat Loss The heat loss that results from the flow of heat through the building materials is called the trans mission heat loss. As shown in Figure 5-1, each material used in a building section, such as a wall, transmits heat. However, each material does so in different amounts because of its inherent "resistance" to heat transmission. The more resistance, the less heat lost. ~~ 3. The difference between the inside and outside temperatures. This relationship may be stated as: where HL(trManncs = W x A x TD HLfrang = Transmission Heat Loss (watts) W = Coefficient of Heat Transmission for Building Section (watts per square foot of surface area per degree of TD) A = Surface Area (square feet) TD = Temperature Difference (degrees F.) Infiltration Heat Loss The heat loss that results from direct exchange of cold outside air with the warm air in the house is called the infiltration heat loss. When windows or doors are opened, the warmer air rushes to the out side, and is replaced by colder-air. Or the cold air may be forced in by the wind (Figure 5-2), through cracks around doors and windows, and through min ute openings in the structure itself. Figure 5-2. Heat Loss by Cold Air Infiltration Figure 5-1. Transmission Heat Losses through Building Materials The amount of transmission heat loss depends on three factors: 1. How well (or poorly) the building materials conduct heat. 2. How much area is exposed to the cold. The amount of infiltration heat loss depends on four factors: 1. The coefficient of infiltration heat loss (specific heat of air). 2. The cubic volume of the room. 3. The number of times the air in the room changes per hour. o 5-1 *> ' ' Uon NJ O 4. The difference between the inside and the out side temperature. This relationship may be stated as: HL.m.f.i.l = 0.0053 x V x CH x TD where HLinfil = Infiltration Heat Loss (watts) 0.0053 = Coefficient of Infiltration Heat Loss (watts per cubic foot of air per degree TD) V = Total Volume (cubic feet) CH = Number of Air Changes (per hour) TD = Temperature Difference (degrees F.) HEAT TRANSFER Since each building material and overall building section transmits different quantities of heat, some measures must be established for the heat transfer relationships. R Thermal resistance is a measure of how poorly a material or a building section trans fers heat. (Note: R for a building section is designated as RT -) Thus R for a material is equal to the recipro cal of any heat transfer coefficient, and: X (X = material thickness in inches) k. R 1_ C Figure 5-3 illustrates the resistance to heat transfer provided by two common building materials like min eral wool insulation and gypsum board. Note that the mineral wool, which is a good insulator, has a high R, and conversely, that gypsum board, which readily transfers heat, has a low resistance. MINERAL WOOL INSULATION As a result, the following basic units of heat transfer have been defined: _ W This is the overall coefficient of heat trans mission for a building section (such as a complete wall, ceiling, floor, etc.). W is a measure of the heat loss in watts which will pass through a one square foot area of the building section for each degree of tem perature difference between surfaces. U This is also an overall coefficient of heat transmission for a building section. U is similiar to W, except that it expresses heat loss in Btu's per hour passing through one square foot of the section per degree tem perature difference. k Thermal conductivity measures the heat transmission characteristics for one inch of a material. It is used only where heat transfer is directly proportional to material thickness. It is expressed as the number of Btu's per hour that will pass through one square foot area per inch of material thick ness per degree temperature difference. It can also be stated with watts as the heat unit. C Thermal conductance measures the heat trans mission properties of a material having a specific thickness. It is expressed as the number of Btu's per hour that will be trans mitted through one square foot area of the des ignated material at specified thickness per de gree temperature difference. It can also be stated with watts rather than Btu's per hour as the heat unit. k= X = 4 inches R = X k = 4 0.27 14.80Hr~ Sq~ Ft~ F Btu 3 1/2" GYPSUM BOARD C = 2.25 Hr. Sq. Ft. F r I* =0.45 Hr. Sq. Ft. F L 2. <23 gtu Figure 5-3. Calculating Resistance (R) from Conductivity (k) and Conductance (C) R-p for a building section is equal to the total resis tance of the materials and other heat transfer factors of the building section (such as dead air spaces and air films). Therefore: RT=R1+R2+R3 + - ^ Figure 5-4 shows the resistance to heat transfer pro vided by a complete wall section. It is interesting to note that four inches of mineral wool insulation (Fig ure 5-3) provides almost three times more resistance to heat transfer than the complete wall section in Figure 5-4. o 'jo t-J 5-2 Item R1 R2 R3 R4 R5 R6 rt Material Outside air film (15 MPH) Wood siding 25/32" insulating sheathing Air space 1/2" gypsum board Inside air film (still air) R Value 0.17 0.85 2.17 0.97 0.45 0.68 5.29 Figure 5-4. Calculating R^, for a Wall Section Item R1 R2 R3 R4 R5 R6 rt Material Outside air film (15 MPH) Wood siding 25/32" insulating sheathing 3-1/2" mineral wool 1/2" gypsum board Inside air film (still air) R Value 0.17 0.85 2.17 13.00 0.45 0.68 17.32 u=ritr Btu/Hr./Sq. Ft./F 0.06 Figure 5-5. Calculating RT and U (or W) for a Wall Section The heat transfer properties, k, C, and R, of most construction materials, airspaces, and air films, are listed in Table 7-2. practical to use the electrical equivalent of Btuh, which is watts, Overall Coefficients of Heat Transmission The relationship between the total resistance (RqO of a building section, and the overall coefficients of heat transmission is as follows: Since 3.413 Btu per hour provides the same amount of heat as 1 watt, the relationships between these heat energy units can be expressed as follows: Convert Btuh to Watts W = (when R values are expressed in watts) T U = --(when R values are expressed in Btu's t per hour) To find the U or W factor for a building section, such as the insulated wall in Figure 5-5, the follow ing steps are necessary. First, find the R value of each element from Table 7-2. Then, add the R's to determine R^. Finally, calculate U (or W) by divid ing R-p into 1. HEAT ENERGY EQUIVALENTS For many years, Btu's per hour was the measure for heat loss and heating requirements. However, with the advent of electric heating, it became popular and W U/3.413 = 0.293U Kwat..ts r watts KBtuh/3'413 = -293 KBtuh CBtuh/3,413 = 0-293 c Btuh Rwa.t.ts = 3.413 RB,,.tuh. Convert Watts to Btuh U = 3.413 W KnBt. uh. = 3.413 Kwat,,ts CnB^tu,h =3.413 Cwat.t.s RnBt.u,,h = Rwatts/3.413 = 0.293 Rwatts oB00 NJ oMOn tO 5-3 INSULATION Effective insulation lowers operating costs, improves comfort, and reduces the initial cost of the heating system. The All Weather Comfort Standard of the National Mineral Wool Association has been estab lished as a guide to the minimum amount of insulation to use in electrically heated buildings. All Weather Comfort Standard The All Weather Comfort Standard of the Mineral Wool Association stipulates that enough insulation be used to achieve the heat transmission values shown in Table 5-1. Table 5-1. All Weather Comfort Standards Building Section U RqBt,u W ^atts Ceilings* Walls Floors over vented crawl spaces 0. 05 0. 07 0. 07 20. 0 14. 3 14. 3 0. 0147 0. 0223 0. 0223 68.0 45. 6 45. 6 Item R1 R2 R3 R4 R5 rt Material Air film (still, flow down) 13/16" Hardwood Building Paper 5/8" Plywood Air film (still, flow down) R Value 0.92 0.68 0.06 0.78 0.92 3.36 u=i- Btu/Hr. /Sq. Ft. /F rt 0.30 Figure 5-6. Determining Amount of Insulation Required For quality installations, minimum heat loss, and operating economy, ceilings of THERMALUX heated homes should be insulated to R-24 standards. This gives a U of 0.04. Determining the Required Insulation In order to determine the amount of thermal insula tion required to satisfy the All Weather Comfort Standards, find total R for the uninsulated building section and subtract that from the Standard value of For example, Figure 5-6 illustrates a common floor construction before insulation is added. The R values were obtained from Table 7-2, and R^ and U were calculated as explained for wall sections. Assuming the floor is over a vented crawl space, the All Weather Comfort Standards will be met if enough insulation is added to provide 11 units of resistance. This was determined by subtracting the R of the un insulated floor (3.36) from the Standard value of Rq(14.3), or 14.3-3.36 = 11. The same procedures used to calculate insulation re quired in a floor to meet All Weather Comfort Stand ards can also be used to determine the amount of (and the R-value for) insulation for walls and ceilings. Specifying Insulation For years the insulation industry had specified in sulation according to thickness. Thus, it was very popular to refer to so many inches of insulation in the ceiling, walls, and floors. Even in the early stages of electric heat marketing this was done, and the famous 6-4-2 formula (6 inches in ceilings, 4 inches in wall and 2 inches in floors) became well known. However, inches is a poor measure of insulation, since different materials have significantly different insulating properties. For example, the k-value of mineral wool is 0.27, and a 3 inch batt has an R of 11. But glass wool, with a k of 0.30 requires a batt 3.33 inches thick to provide 11 units of installed re sistance. In an endeavor to provide an accurate way of speci fying insulation, the mineral wool industry has adopted the R value designations for standard pro ducts. Accordingly, products are identified by in stalled resistance values, such as R-ll, R-13, R-19, and R-24. All of these basic products meet or ex ceed the All Weather Comfort Standards when pro perly installed. U.S. G. THERMAFIBER mineral wool insulation ful fills all the requirements for effective building in sulation. It is available in batt, blanket, or nodular form. It combines the qualities of convenient pack aging, ease of installation, low cost, durability, and fire, water, and vermin resistance. THERMAFIBER insulation batts are designated by the "R" value of the installed insulation. 5-4 BB029 0523 HEAT TRANSMISSION OF WINDOWS AND DOORS The he.it transmission of windows, doors, glass block sections, and skylights is very complicated to deter mine accurately. Therefore, results have been worked out experimentally for many popular pro ducts, then averaged, and the data tabulated as fol lows. Windows Find the coefficient of heat transmission for windows as follows: Find the W of the giass from Table 5-2. Skylights Find the coefficient of heat transmission for skylights as follows: Find the W of the glass from Table 5-4. Table 5-4. W of Horizontal Glass Sheets (watts per square foot per F) Air Space One Sheet Two Sheets None 1/4" 1/2" or more Outdoor exposure Indoor exposure 0. 41 0. 28 0. 20 0.17 0. 19 0. 16 Table 5-2. W of Vertical Glass Sheets (watts per square foot per F) Air Space One Sheet Two Sheets None 1/4" 1/2" or more Outdoor exposure Indoor exposure 0.33 0. 22 0.18 0. 15 0. 16 0. 13 Now multiply the W of the glass by the correction factor in Table 5-3. Table 5-3. Correction Factors for Window Framing Type of Window Sash % Glass Single Glass Factor Window Double Glass with Storm Sash Wood Wood Steel Aluminum 80 60 80 80 0.9 0. 95 0.8 0.85 1.0 1. 20 1. 1 1.30 0. 9 0.8 1.0 1. 1 Now multiply the W of the glass by the appropriate correction factor in Table 5-3 to get W of the sky light. Hollow Glass Block The W of wall sections made of hollow glass block is listed in Table 5-5. Table 5-5. W of Wall Sections of Hollow Glass Block (watts per square foot per F) Size of Block Outside Wall Section 5-3/4"x5-3/4"x3-7/8" thk 7-3/4" x 7-3/4" x 3-7/8" thk 11-3/4" x 11-3/4" x 3-7/8" thk 0. 18 0. 17 0. 15 Inside Wall Section 0. 14 0. 13 0. 12 Doors __ The W of solid wood doors is listed in Table 5-6. Table 5-6. W of Solid Wood Doors (watts per square foot per F) Example: A single pane window with storm sash covers a wall opening of 4' 3" x 3' 6". The sash is of wood and occupies about 20% of the opening. Then, from Table 5-2, the W value of the glass is 0.16 and, from Table 5-3, the correction factor for a wood sash window (where the glass area is 80%), that has a storm sash, is 0.9. Now 0.9x0.16 = the W value of the window. Window heat loss is cal culated by basic heat loss formula, HL = W x A x TD. Nominal Thickness 1" 1-1/4" 1-1/2" 1-3/4" 2" 2-1/2" 3" 5-5 Actual Exposed Thickness Door With Glass Storm Door 25/32" 1-1/16" 1-5/16" 1-3/8" 1-5/8" 2-1/8" 2-5/8" 0. 19 0. 16 0. 14 0. 14 0. 13 0. 11 0. 09 0. 11 0. 10 0. 09 0. 09 0. 08 0. 08 0. 07 vo TEMPERATURE DIFFERENCE Temperature difference (TD) is the difference, in de grees Fahrenheit, between the inside design temper ature and the outside design temperature. This can be expressed as: TD = T inside - T outside Calculating Temperature Differences Assume Inside Design Temperature is 70F. One house is located in an area where Outside Design Temperature is 10F, while a similiar house is sit uated where Out: ide Design Temperature is 20F be low zero. What are the design TD's for these houses? The Isotherm Map of Winter Outdoor Design Temper atures (Figure 7-2) can be used to get approximate data for localities not listed in Table 7-1. Perhaps a better procedure is to check with the nearest Weather Bureau office and local heating authorities to determine the accepted Outside Design Temper ature. FINDING TRANSMISSION HEAT LOSS All of the factors which are used in typical transmis sion heat loss calculations have now been considered in this Chapter. Of course, the basis for these cal culations is the formula HL = W x A x TD, which Figure 5-7 applies, determining heat loss for a bed room. Calculate from formula: TD = T^^ - Toutside House 1: TD = 70 - 10 = 60F House 2: TD = 70 - (-20) = 90F Inside Design Temperature Since the normal inside temperature for homes is 70, this is the established inside design temperature. However, for bathrooms, "an inside design temperature of 75 or 80 should be used. In areas such as playrooms and workshops, where people are active and generate more body heat, a lower inside design temperature should be used. Sim ilarly, in rooms where machinery or appliances gen erate heat, for example laundry rooms, an inside de sign temperature of 60 or 65 may be used. OUTSIDE TEMPERATURE -20F INTERIOR ROOM 70F WALL 1 WALL 4 7 DOUBLE PANE WOOD SASH WINDOWS ROUGH OPENING 3' x 4' BEDROOM 9`-6" x 10"-6" (CEILING HEIGHT 8'-CT) An even lower inside design temperature should be used for rooms not designed as living areas. The inside de sign temperature for a heated garage, for example, can be figured at about 35 to 40. In most localities, there are generally accepted in door design temperatures proved out by long experi ence and used by most heating system designers. These are probably the ones best suited to the area and should be used in THERMALUX System design. Outside Design Temperature To provide enough heating capacity for severe winters, it is necessary to use the coldest temperature which frequently occurs during a heating season as the out side design temperature. However, it is not neces sary to use the coldest temperature ever recorded for the area, for the temperature would rarely drop to that level. The Outside Design Temperature specified for any area is the result of considerable judgement and ex perience. These values for selected localities are shown in Table 7 -1. INTERIOR ROOM 70F Building Section Wall 1 1 Wall 2 J Wall 3 Wall 4 Floor Ceiling Window 1 1 Window 2 J Total HL W 0.020 - 0.020 0.015 0.153 Area Sq.Ft. 136 - 100 100 24 TD Heat Loss Watts 90 244 00 00 90 180 90 135 90 333 892 Figure 5-7. Finding Transmission Heat Loss BB029 0525 5-6 Temperature Difference (TD) Inside design temperature, as shown in Figure 5-7, is 70F and the outside design temperature is -20F. Therefore, on exterior walls 1 and 2 TD = 70 (-20) = 90F. On walls 3 and 4 the TD is 70 - 70 = 0. Thus, there will not be any heat loss through those sections. It is recommended that 2" thick edge insulation be used, but a 1" thickness is acceptable. Figure 5-8 illustrates the location of edge insulation around floor slabs. Floor and Ceiling Area Floor and ceiling area, shown in Figure 5-7, is 9' 6" by 10' - 6", or 9.5 x 10.5 = 99.75 sq. ft. (approxi mately 100 sq. ft.). The designed W of the floor is 0.020. Therefore, HL.trans = W x A x TD = 0.020 x 100 x 90 = 180. INSULATION (RECOMMENDED) INSULATION INSULATION The ceiling heat loss for the same room would be; HL,trans = W x A x TD = 0.015 x 100 x 90 = 135 watts, Assume the same room has an 8' ceiling. The gross area of exterior walls 1 and 2 is (9.5' + 10.5') x 8' = 160 sq. ft. Deducting window areas of 24 sq. ft. (2 x 3' x 4') leaves 136 sq. ft. (160 - 24) of net area that have W = 0.020. Then, HL = W x A x TD = 0.020 x 136 x 90 = 244 watts. Window Area The two window openings in Figure 5-7 cover an area of 24 square feet. If each is a double pane window with a wood sash and the two panes of glass are 1/4" apart, the glass covers 60% of the opening. It can be determined from Tables 5-2 and 5-3 that the W-factor for these windows is 0.18 x 0.85 = 0.153. Therefore, HL,trans = W x A x TD = 0.153 x 24 x 90 = 333 watts, Floor Slab Heat Loss Tests have shown that heat loss through a concrete floor slab at or near grade level can best be figured on the basis of its perimeter. The heat loss varies with the amount of edge insulation and with outside design temperature, as shown in Table 5-7. Table 5-7. Floor Slab Heat Loss (watts per lineal ft. exposed slab edge) Figure 5-8. Examples of Edge Insulation Around Floor Slabs Basement Heat Loss On cold winter days, the temperature of the ground a foot or more below the surface is higher than the out side temperature, as Figure 5-9 illustrates. There fore, the design heat loss through the part of the base ment wall which is more than a foot below grade and through the basement floor is less than that through the higher part of the wall. In figuring basement heat loss, use the outside design temperature to find the TD for the wall from one foot below grade and up. For the wall below that and for the basement floor, use an outside design temperature equal to well water temperature at depths of 30 to 60 feet. The nearest Weather Bureau office will have the approximate well water temperature for your area, which varies from about 40F to about 60F. Example: A 10" concrete basement wall is 24' long and 7' high, 2' of this above grade. The-outside de sign temperature is -10F and well water temperature in the area is 50F. The basement is heated. What is the design heat loss? The W of a 10" concrete wall is 0.37 watts per square foot per F. For the top 3' of the wall, the design TD is 80 and the area is 72 square feet. For the bottom 4 feet (area 96 sq. ft.) the de sign TD is (70F - 50F.), or 20F. Therefore? HL.trans = 0.37 x 80 x 72 + 0.37 x 20 x 96 = 2110 + 700 = 2810 watts. Outside Design Temperature -20 to -30 -10 to -20 0 to -10 Above 0 24" Insulation (Horizontal + Vertical) 2" thick 1" thick 15 17 13 15 11 13 9 11 No Insulation 22 19 18 15 5-7 Indoor Temperature Differences In calculating the heat loss for a room, consider the heat loss to other rooms as well as to the outside. In a room over an unheated basement, for example, heat is lost through the floor to the basement. The same is true for a room over a crawl space, and for heat loss through a ceiling into an unheated attic. In a room next to an enclosed garage, there is a heat loss * to the garage. S Aj INSULATION However, with the same design temperature conditions, the heat loss through an 8' x 24' wall (area = 192 sq. ft.), with a W of 0.0233, into an insulated garage would be: HL.trans = 0.0233 x 192 x 35 = 155 watts, Here again, in any community, there are probably de sign temperatures widely accepted and used in heating system design. Use these accepted values when making heat loss calculations. In fact, this applies even to outdoor design temperatures. If common local practice is to use a figure somewhat different from that in Fig ure 5-10 or Table 7-1, use the commonly accepted figure. Figure 5-9. Typical Basement Wall Section In general, unheated rooms and spaces which are en closed by insulated building sections with about the same W and about the same outdoor exposure as the rest of the house will have a design temperature about half way between the outdoor design temper ature and the indoor design temperature for the rest of the house. Figure 5-10 illustrates acceptable in door temperature differences. FINDING INFILTRATION HEAT LOSS The total air volume in a room will change completely from 1/2 to 2 times per hour. Each time the air is changed, the new air must be heated from the outside temperature to the inside temperature. The number of air volume changes depends on many things such as: tightness of construction; insulation; the number, area, and type of windows and doors; and, prevailing wind forces. Usage also makes a big differ ence. Frequent opening and closing of an outside en trance door to a room will substantially increase in filtration heat loss for that room and adjacent rooms. As noted earlier in this chapter, the amount of infil tration heat loss depends on these factors: 1. Coefficient of infiltration heat loss. 2. Temperature difference between inside and outside air. 3. Air changes per hour. 4. Volume. Crawl Space Vented T = t o t. - t Sealed T = --g-- (not recommended) Room Air Changes The number of air changes per hour (CH) can be esti mated by using Table 5-8. Table 5-8. Room Air Changes Per Hour Figure 5-10. Design Temperature Differences Thus, for a well insulated, 12' x 12' floor with a W factor of 0.02 above a vented crawl space, with 70F inside temperature and 0F outside temperature, the heat loss is: HL,trans = W x A x TD HL.trans = 0.02 x 144 x 70 = 207 watts, Type of Room 1 side exposed 2 sides exposed 3 sides exposed 4 sides exposed Entrance Hall 5-8 Air Changes Per Hour Without Storm Sash on Windows and Doors With Storm Sash on Windows and Doors 1 1-1/2 2 2 2 to 3 1/2 3/4 1 1 1 to 1-1/2 The infiltration heat loss for the room (Figure 5-7) discussed in transmission heat loss is found as fol lows. The size of the room is 100 square feet and the ceil ing height is 8 feet. Therefore, the volume is 100 x 8 = 800 cubic feet. The room has two sides exposed and has storm sash. Thus, from Table 5-8, the air changes per hour (CH) = 3/4. Recalling the formula for infiltration, heat loss for the room is: HL.in.f.i.l = 0.0053 x V x CH x TD HL.in.f.i.l = 0.0053 x 800 x .75 x 90 = 286 watts The Area Calculator This is used for calculating areas of floors, ceilings, walls, windows, doors, and any other surfaces through which heat will be transmitted. The calculator is designed with dimensions (in feet) noted across the top and vertically on the left. Area is determined by reading from the dimension scales to an intersect in the chart. For example, the room in Figure 5-7 had dimensions of 9-1 /2' and 10-1/2'. Read across the top of the area calculator to the column headed 9-1/2'. Then read down the left scale to the column headed 10-1/2'. Read out into the calculator to where columns intersect. Note figure 100, which is the floor area in square feet. FINDING TOTAL HEAT LOSS The total heat loss for a room is the sum of the trans mission heat loss and the infiltration heat loss. HL.tot. a.l = HL,trans + HL.infil Using the room in Figure 5-7 as an example, total heat loss is 892 + 286, or 1178 watts. Of course, the total heat loss for a building is the sum of heat loss for all rooms-and miscellaneous space. Figure 5-11. Using the Area Calculator The Volume Calculator SHORT-CUT METHODS OF FINDING HEAT LOSS The preceeding parts of this chapter covered the basic ways of calculating heat loss. These methods, de rived mathematically and experimentally, are very accurate, proven by years of practice, and are re commended in the "Guide of the American Society of Heating, Refrigerating and Air-Conditioning Engi neers". In addition to the ASHRAE methods for calculating heat loss, there are many other simplified ways that have been devised. The short-cut techniques range from crude, rule-of-thumb approximations up to types such as the THERMALUX Heat Loss Calculator which is very accurate. The Volume Calculator is used to determine the num ber of cubic feet enclosed by a room or structure. This data is then used in calculating heat loss due to infiltration. This calculator, Figure 5-12, is somewhat similar to the Area Calculator. However, volume is deter mined by multiplying floor area by ceiling height, so these are the factors built into the calculator. Again using the room in Figure 5-7 as an example, the floor area of 100 square feet was previously de termined. Now, by locating the number 100 in a col umn headed AREA SQ. FT. on the Volume Calculator, read across to the number 8 in the column for CEIL ING HEIGHT. The figure where the columns intersect is the room volume, 800 cubic feet. An example of the THERMALUX Heat Loss Calculator is located in the back of this chapter. Close exami nation of this practical, time-saving device will re veal that it is based on the ASHRAE heat loss calcula tion methods. Actually, what has been done is to "precalculate" the heat loss formulas for most popu lar constructions, amounts of insulation installed, and for established design temperature differences. By doing the arithmetic calculations in advance, the heat loss data can be presented in handy nomagraph form. These technical aids are easy to use, and both speed and accuracy will be gained with brief practice. 5-9 Figure 5-12. Using the Volume Calculator '~ W g tvXo> OLD to CO Use of Heat Loss Charts The THERMALUX Heat Loss Calculators are designed with a complete set of charts for every 5 increment of Design Temperature Difference, such as 50F TD, 55F TD, 60F TD, 90F TD, etc. The set of charts for each TD is comprised of individ ual charts for heat loss of different building sections such as walls, ceilings, floors, and windows-doors. Heat loss by infiltration and for concrete slab floors also are determined on separate charts. Since all charts are used in the same way, the room from Figure 5-7 will illustrate how heat loss is easily calculated. From previous calculations the net area of walls 1 and 2 was established as 136 sq. ft. These walls are constructed to meet the All Weather Com fort Standard, and have 3-inches of insulation with an R-value of 11. Using this data, the heat loss can now be determined from the chart illustrated in Figure 5-13. First, locate wall area on left of chart. Read out horizontal ly from the 136 point to the sloping line designated Rll and 3" of insulation. Now read vertically down ward to determine heat loss at the base of the chart. The value is 240 watts, a close approximation of the 244 watts calculated. calculation, incorrect system design, and unaccept able system performance. ANNUAL ENERGY CONSUMPTION The annual consumption of electric power by an elec tric heating system depends upon the length and sever ity of the heating season. To determine annual consumption, a quantity known as Degree Day is used to measure severity of the heating season as gauged by high and low temper atures during the winter. The length or duration of a heating season is based on the total number of Degree Days occurring through the winter in the locality where the building is to be located. Degree Days A degree day (DD) is defined as a day on which the mean temperature is 1 below 65 (64). If the mean temperature of a day is 50, that day is counted as 15 degree days (65 - 50 = 15). This may be ex pressed as DD = 65 - -6------^ z where Thigh and T1qw are the highest and lowest tem peratures recorded for a given day. . For example, if the highest temperature for a given day is 40 and the lowest is 18, the number of de gree days (DD) for that day would be: DD = 65 - = 65 - 29 = 36 The temperature of 65 is chosen as the base for fig uring degree days because long experience has shown that heating generally does not start until the outdoor temperature drops below 65 and stops when the out door temperature rises above 65. Figure 5-13. Using THERMALUX Heat Loss Calculator ACCURACY OF CHARTS The answers determined by using formulas and charts will differ slightly, since the charts are accurate within plus or minus 3%-5%. Such accuracy is well within allowable tolerances, considering the variations that can be encountered from construction, insulation, and other job-oriented factors. Over the years, heating experience has shown that the amount of fuel consumed varies in direct proportion to the number of degree days. Therefore, the Weather Bureau has records of the average number of degree days per year at the weather stations throughout the country. The degree days for many cities are shown in Table 7 -1. Annual Consumption Formulas Two formulas are generally used in estimating how much electricity will be required annually to heat a building; the National Electrical Manufacturers Asso ciation (NEMA) formula; and, the Federal Housing Administration (FHA) formula. While charts are convenient time-savers, it is im portant to be fully aware of how they were derived and what limitations they contain. Incorrect use of a chart can result in gross errors in the heat loss The FHA formula is: KWH = HL TD x x DD 185 & % 5-10 Xi> where KWH = Total annual consumption in kilowatt-hours HL = Design heat loss in Btu/hr DD = Annual number of degree days (see Table 7-1) TD = Design temperature difference (see Table 7-1). Example: A house with design heat loss of 30100 Btu/hr is in Chicago where DD is 6310 and TD is 80. What is the annual consumption of electricity by the FHA formula? 30100 x 6310 189931000 = 80 x 185 " 14800 KWH = 12833 kilowatt-hours The National Electrical Manufacturers Association (NEMA) formula is where KWH = HL x DD TD x C HL = Design heat loss in kilowatts C = Usage factor (usually 17.0) DD = Annual number of degree days (see Table 7-1) TD = Design temperature difference (see Table 7-1). Example: Using the same house as in the previous ex ample, what is the annual consumption? To find HL, convert the design heat loss from Btu/hr to kilowatts. then annual heating cost is readily calculated. Simply multiply consumption by the local electric heating rate. Example: Annual consumption for heating is 12868 kilowatts hours (results from NEMA formula when C = 18.5. Note similiarity with FHA data). Electric heating rate is 1.25 cents per kilowatt hour. What is annual heating cost? Heating Cost = KWH x Rate = 12868 x 1.25 cents = $158.58 Another way to determine heating cost is with the THERMALUX Heating Cost Calculator, included with the charts at the end of this chapter. To use the chart proceed as follows: 1. Draw a line from the center of the target to the outside design temperature (top left scale) for your climate. 2. Draw a line from the center of the target to the power rate (top right scale) for your area. 3. Draw a vertical (straight up) line from the winter degree days for your area (bottom left scale). 4. Draw a horizontal line from the intersection of the lines drawn in steps 1 and 3 to the line drawn in step 2. 5. Draw a vertical line (straight down) from the intersection of the lines drawn in steps 2 and 4. 6. Read the annual operating cost per kilowatt of heat loss at the point where the line drawn in step 5 intersects the bottom scale. OUTSIDE DESIGN TEMPERATURE POWER RATE HL = WT= 8-819 kilowatts KWH " 8.819 x 6310 80 x 17.0 _ ~ 946097 80 KWH = 11826 kilowatt-hours Notice that using the NEMA formula gives a different answer than the FHA formula. That is because NEMA uses a C-value of 17.0 while the FHA formula is based on C = 18.5. Since the factor C is a vari able, selected to adjust for "usage" of the residence the correct value is difficult to determine. There fore, if it is common practice in the particular local ity to use some value other than 17.0 for C in figuring annual consumption of electricity, follow the local practice. Generally, the local electric utility is the best source of information in such matters. ANNUAL HEATING COST After the annual fuel consumption has been determined, WINTER DEGREE DAYS PER KILOWATT OF NEAT LOSS Figure 5-14. Using THERMALUX Heating Cost Calculator When the same data from the previous example are applied to the calculator, results are as follows: An nual operating cost per kilowatt of heat loss is ap proximately $18.00. Since the heat loss was deter mined at 8.819 kilowatts, total annual cost will be about: $18.00 x 8.819 = $159.05. Note the very accurate comparative results between charted and t calculated costs. A> DESIGNING THE THERMALUX SYSTEM Once the heat loss calculations for the building are completed, the data is available to finalize the Sys tem Design. First, the quantity of Heating Panel required to make up for calculated heat loss in each room must be de termined. Since THERMALUX Heating Panels have heat output of 15 watts per square foot, the total foot age of Heating Panel needed is found by dividing heat loss by 15. Example: The room in Figure 5-7 has a total heat loss of 1178 watts. Footage of THERMALUX Heating Panel needed to satisfy heat loss: 117fi THERMALUX Panel Required = = 78 = 80 sq.ft. Ceiling Irregularities Wherever possible, use Filler Panel where there are ceiling fixtures such as light fixture junction boxes, exhaust fans, duct work, and pipes. Heating Panels adjacent to Filler Panels must be se parated by 8" from electrical boxes or conduit and 2" from all other metal located in Filler Panel areas as shown in Figure 5-16. When the amount of heating panel needed for each room has been found, the panel sizes and layout may be determined. Considering the 9-1/2' by 10-1/2' dimensions of the example room, and the fact that 80 sq. ft. of heating panel are required, the first choice would be to use two 4' x 10' panels. Since the goal is to balance heat evenly over the room area, the panels must be located in proximity to the places of greatest heat loss. This means favoring panel placement by outside walls and cold areas, such as doors and windows, as indicated in Figure 5-15. However, compromises are always necessary since good design will not leave large areas of the ceiling without heating panel. 4' x 10' Figure 5-16. Light Fixture Junction Boxes Adjacent to Heating Panels If cutouts in Heating Panels are necessary, provide the following minimum clearances from any edge of the cutout: 2" from the copper electrode, 6" from the end of the panel and 24" from the edge of an adja cent cutout in the same panel as shown in Figure 5-17. Make no more than one cutout in a panel 8' or less in length, and make a maximum of two cutouts in longer panels. Cutouts in A-30-24.48 panels (2' . wide heating area) cannot exceed 16-1/2" wide. Each cutout creates a non-heating area in the panel repre sented by the shaded portions of Figure 5-17. To be conservative in design, these non-heating areas must be deducted from the total heating panel area to de termine heat output at 15 watts per square foot. Figure 5-15. Heating Panel Layout Parallel or Perpendicular Installation Heating panels may be installed with their long dimen sion either parallel or perpendicular to joists. Layout of the System is best done on tracing paper over the floor plan. After the design is completed, suitable details and notations can be made on the working drawings. Perpendicular installation, where possible, is the most desirable since joist alignment and spacing are not critical and the wiring recesses are simpler to construct. 5-12 BB029 0531 <r VENT DUCT, 2" MIN. ] JL 2" MIN 1 o SOIL PIPE 6" MIN. 1 HEAT LOSS AREA T -------24" MIN.-- 2" MIN. RAD. r \ 8" MIN. = rr LIGHT FIXTURE 'JUNCTION BOX / : ELECTRODE Jl / HEAT LOSS AREA --------------- ! .. . _ J r 00 z_ L LIGHT FIXTURE .JUNCTION BOX. ' /) 2" MIN. Figure 5-17. Clearances Required by Typical Cutouts in a Heating Panel Wiring Recesses Wiring recesses, as explained in Chapter 4, are used to completely enclose the Heating Panel feeder wires in non-combustible, non-conductive material. Typical types of recess construction are described and illus trated in Chapter 6._ Locate the Heating Panels so that the wiring recesses have a straight line shape wherever possible, locate bushings towards the center of the building or gables, away from eaves. The electrical raceways from the junction box to the bushing will be awkward to install in the attic when the bushing is too close to an eave. For the same reason, don't locate a wiring recess alongside an eave. Where the recess must be against an outside wall, make it the wall on the gable side. An inside wall is the most desirable location for the wiring recess and usually results in the simplest most economical electrical work. Designate the required wiring recess depth on the System Design. Depth is readily determined since when one or two panels are being wired through one recess, only a 1/4" depth is needed, although a 1/2" deep recess will be completely acceptable. When three or more panels are being wired through one re cess, a 1/2" depth is needed. Always build the re cess that best fits the construction situation and meets or exceeds wiring recess depth requirements. panel area by 8. In the example room, 80 feet of Heating Panel are required. Therefore, current will be 80/8 = 10 amperes. Determining Size of Branch Circuit Wiring The size electrical wire which must be used in branch circuits depends on the amount of current which will be carried, and usually is stipulated in the electrical code. Table 5-9, based on the National Electrical Code, in dicates the maximum current and quantity of Heating Panel load which can be handled by 2-and 3-wire cir cuits of various sizes. Table 5-9. Heating Branch Circuit Capacities Branch Circuit Conductor Size Max. Load-Amps (20% Derated) Maximum Installed Area of Heating Panel 2-Wire 3-Wire Circuit Circuit #14 12 #12 16 #10 24 96 192 128 256 192 384 Choice of 2-Wire or 3-Wire Circuits ELECTRICAL DESIGN Circuits should always be chosen with the smallest wire size that can handle the design load, Figure 5-18 The quantity of Heating Panel which must be installed, illustrates how this is done. Note that current load and the amount of current that the panels will draw, is on each leg of 3-wire circuit are almost equal. This the basis for all the electrical design work. balance must be attained for acceptable performance. In addition, a combination of 3-wire circuits, (which Determining Room Current have the electrical capacity of two 2-wire circuits), Since THERMALUX Heating Panels draw 0.125 amps should be used for economy. (1/8 amp) of current per square foot, the total current Usually, the electrician can readily determine the best for a room can be readily determined. Simply divide type of circuitry if the current loads are known. 5-13 s o Nj - o LD GJ NJ BEDROOM 2 9.6 AMP LOAD BATH 3 3.4 AMP LOAD KITCHEN 4 8.1 AMP LOAD CLOSET CLOSET BEDROOM 1 10.4 AMP LOAD LIVING 5 21.4 AMP LOAD Room Current Circuit 1 10.4 3-wire #14\ .. , 2 9.6 o3-wire #14a J> combined 3 3.4 2-wire #14\ ,. , 4 8.1 o2-wire #1a4)? combined 5 21.4 2-wire #10 Figure 5-18. Heating Circuit Loads and Sizes Overload Protection Panel Feeders Overload protection (fuse or breaker) is required for each branch circuit conductor, exclusive of neutral conductors. If a load current does not equal a stand ard fuse or breaker rating, use a fuse or breaker having the next higher rating. The branch circuit cables from the junction boxes to the panels are referred to as panel feeders. These cables must be single conductor Type UF (Under ground Feeder) wiring. Only #12 and #10 size con ductors fit the THERMALUX Electrode Connectors. Locating Junction Boxes Locate a junction box close to the wiring recess in each room or area. The junction box must be acces sible for removal of the cover and inspection of the wiring. Attic, wall, and floor locations are all con sidered accessible. Control Relays Use THERMALUX Type 706 double control relays wherever possible for greater economy. Type 705 single control relays should be used where only one additional circuit is required. The Type 706 relay can handle a 3-wire circuit with maximum current of 44 amperes, and can be controlled by one Type 820E low voltage thermostat. Also, the 706 relay can serve two 22 amp circuits, each controlled with separate thermostats. The 705 relay is designed for one 22 amp circuit with an individual thermostatic control. The recommended location for control relays is at or near the service entrance. However, in certain cases it may be more economical to locate the con trol relays near the rooms. When this is the case, one overload protector may be assigned to handle several small room loads. The size of the overload protector and the size of the wire from the overload protector to the control relays must be large enough to handle the total load. Locate the bushed fittings, bushings, or feed-through holes as close to the branch circuit junction box as possible so that the wire runs are not unnecessarily long. Locate the bushed fittings, bushings, or feed-through holes away from eaves or other inaccessible locations. Plan recess wiring to keep adjacent electrode con nectors at the same potential. Use Table 5-9 to determine panel feeder wire size (but no smaller than #12 conductor). Thermostat Location Each room or area should be equipped with its own thermostat to provide just the right amount of heat for the room. Adjoining rooms with a 30" or other standard size door opening between them may have significantly different temperature requirements. In Figure 5-19, for example, room A has a greater heat loss through outside walls than room B, and a thermostat in A would provide too much heat for B, while a thermostat in B would not provide enough for A. For comfort and economy, each room should have a separate thermostat. Areas or rooms separated by large archways or small divider partitions may use a common ther mostat. This can be done where temperatures in both rooms or areas varies only a negligible amount. 5-14 BB029 0533 The thermostat must be located as far as possible from points of maximum heat loss. Locate the ther mostat on an inside wall away from doors, windows and exhaust fans. The thermostat must also be in a position to "see" a heating panel within the room from the shortest possible distance without obstruction. Locate the thermostat approximately 52" above the floor. Service Drop To determine the size of the service drop required, determine the service drop without electric heating and add the total current draw of the heating system. A 200-ampere service drop is typical of the average single-family dwelling with THERMALUX Electric Radiant Heating. THERMOSTATS INSIDE OUTSIDE WALL Figure 5-19. Thermostat Location 5-15 a g to v5 Ocn to THEftMALKJX DESIGN DATA SHEET NAME____ ADDRESS BUILDER-------------------------------ARCHITECT--------------------------DRYWALL CONTRACTOR-- ELECTRICAL CONTRACTOR. UTILITY REPRESENTATIVE- PHONE. PHONEPHONEPHONE. PHONEPHONE JOB NO_____________ DATE________________ THERMALUX COST * INSTALLED AREA HEATED_____ COST/SO. FT. $ CONNECTED LOAD COST/KW S___ HEATING COST S -SO. FT /SO. FT ____ KW ____ /KV\ ____ /YR CONSTRUCTION: ____ NEW;__REMODEL;_____ADDITION;_____RESIDENTIAL;____ COMMERCIAL;_____FRAME;_____MASONRY VENEER;_____ALL MASONRY; OTHER (Describe):. INSULATION: RECOMMENDED SPECIFIED CEILING _________________ _______________ WALL _________________ _______________ FLOOR _________________ _______________ SLAB_________________ ______________________ BASEMENT WALLS _________________ _______________ CEILING:BLOWN;BATT MATERIAL: MINERAL WOOL OTHER; TYPE: FLOOR:___ OVER HEATED BASEMENT;____ OVER UNHEATED BASEMENT; ___ OVER VENTED CRAWL SPACE WINDOWS-DOORS WINDOWS:SINGLE GLASS; ____________ DOUBLE GLASS; DOORS:SINGLE; ____________ STORM DOORS STORM SASH MOISTURE CONTROL VENT FANS:KITCHEN;. HUMIDISTATS:KITCHEN;. VAPOR BARRIERS:________________________ MISCELLANEOUS:. ____________ BATHROOMS; ____________ BATHROOMS; WALLS; TYPE____________ CEILING; TYPE___________ LAUNDRY LAUNDRY DESIGN DATA: TD ANNUAL OPERATING COST: F; DEGREE DAYS. $ *KW = S. (J/KW) (KW INSTALLED) ; COST/KWH QUOTATION: /YR. TOTAL MATERIAL *. TOTAL LABOR S. TOTAL DIRECT COST J. OVERHEAD S. PROFIT J. PRICE QUOTED $ s ODO M LD O U1 LtoH JOB ITEM I QUANTITY J UNIT COST [ TOTAL COST I NOTES HEATING BRANCH CIRCUITS THERMOSTATS/CONTROLS HEATING PANEL WIRING AUXILIARY EQUIPMENT INSTALL FIRST LAYER-THERMALUX INSTALL FINISH LAYER-THERMALUX JOINT FINISHING-CEILING TOTAL LABOR COST TOTAL COST LABOR/MATERIAL H-20 U.5.G. Rev. 11-44 aCoD CVOO Ot_n UJ <Ti Printed in U S. A. MiltttiVM/: L Us\ HEAT LOSS WORK SHEET /'VTVv JOB NAUF ADDRF^C ROOMS A BUILDING SECTION ROOM No. 1 CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Doors) INFILTRATION ROOM No. 2 CEILING * FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Ooors) INFILTRATION ROOM No. 3 .' CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Doors) INFILTRATION ROOM No. 4 CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS: '' ' ` ' . DOORS NET WALL (Less Windows A Doors) INFILTRATION ROOM No. 5 CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Doors) INFILTRATION H-?t IJ S G 7/64 .Inh No DIMENSIONS AREAS A VOLUME HEAT LOSS-WATTS .............................. Sq. Ft. Sq./Lin. Ft. Sq. Ft. liiiiiii Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS. WATTS Sq. Ft. Sq./Lin. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS, WATTS ^ Sq. Ft. * Sq./Lin. Ft. Sq. Ft. lit* Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS, WATTS - Sq. Ft. Sq./Lin. Ft. Sq. Ft. . Sq. Ft. . Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS, WATTS / Sq. Ft. Sq./Lin. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS, WATTS NOTES ' % 1 Printed in U- 5. A BB029 0537 ROOM & BUILDING SECTION ROOM Nb. 6 CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Doors) INFILTRATION DIMENSIONS AREAS A VOLUME HEAT LOSS-WATTS ' ' \ -'j ; F Sq. Ft. Sq./Lin. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft. TOTAL HEAT LOSS, WATTS ROOM No. 7 CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS DOORS NET WALL (Less Windows A Doors) INFILTRATION Sq. Ft. Sq./Lin. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Sq. Ft. Cu. Ft, TOTAL HEAT LOSS, WATTS ROOM No. 8 ! CEILING FLOOR (Area or perimeter) TOTAL OUTSIDE WALL WINDOWS Sq. Ft. Sq./Lin. Ft. Sq. Ft. lilllililli Sq. Ft. DOORS NET WALL (Less Windows A Doors) Sq. Ft. Sq. Ft. INFILTRATION Cu. Ft. TOTAL HEAT LOSS, WATTS BASEMENT . . FLOOR Sq. Ft. TOTAL WALL ABOVE GRADE Sq. Ft. WINDOWS Sq. Ft. DOORS Sq. Ft. NET WALL ABOVE GRADE Sq. Ft. TOTAL WALL BELOW GRADE Sq. Ft. INFILTRATION Cu. Ft. ROOM 1 TOTAL HEAT LOSS, WATTS SUMMARY-HEATING SYSTEM DESIGN HEAT LOSS--WATTS THERMALUX SO. FT. OR EQUIP. SIZE CURRENT AMPS. CIRCUIT SIZE 2 3 4 5 6 7 B BASEMENT TOTAL NOTES NOTES I a 03 o to vO O LFl LO co 600 575 550 525 500 475 450 425 400 375 350 325 300 275 250 225 200 175 150 125 100 75 50 25 0 -0<35 s 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 HEAT LOSS-WATTS X THERMALVX HEAT LOSS CALCULATOR NET WALL HEAT LOSS ROOM V O LU M E -C U B IC FEET >50 HEAT LOSS--WATTS THERMALt/X HEAT LOSS CALCULATOR INFILTRATION HEAT LOSS OUTSIDE DESIGN TEMPERATURE 30 --20 --10 0 +10 +20 +30 N POWER RATE 0.5c 1.0c 1.5c 2.0c 2.5c 3.0c Tfrso 6zoaa DEGREE DAYS THERMA LUX HEATING COST CALCULATOR M-24 U S G. 7/64 ANNUAL OPERATING COSTS (PER KW HEAT LOSS) BASED ON NEMA OPERATING COST FORMULA WITH C-FACTOR OF 17 Pf inled in USA. DIM. FT. 1% 2 2% 3 3% 4 4'/2 5 5% 6 6% 7 7% 8 8% 9 9% 10 10% 11 11% 12 12% 13 13>/2 14 14% 15 1% 2 2% 244 446 466 468 688 6 8 10 6 10 12 8 10 12 8 12 14 10 12 16 10 14 16 10 14 18 12 16 18 12 16 20 12 18 22 14 18 22 14 20 24 16 20 26 16 22 26 16 22 28 18 24 28 18 24 30 18 26 32 20 26 32 20 28 34 22 28 36 22 30 36 22 30 38 P3 3% 4 4% 5 5% 6 6% 7 7% 8 8% 9 9% 10 10% 11 11% 12 12% 13 13% 14 14% 15 15% 16 16% 17 17% 18 18% 19 19% 20 4 6 6 6 8 8 10 10 10 12 12 12 14 14 16 16 16 18 18 18 20 20 22 22 22 24 24 24 26 26 28 28 28 30 30 [_ C 8 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34 36 36 38 38 40 40 8 8 10 12 12 14 16 16 18 18 20 22 22 24 26 26 28 28 30 32 32 34 36 36 38 38 40 42 42 44 46 46 48 48 50 10 10 12 14 16 16 18 20 22 22 24 26 28 28 30 32 34 34 36 38 40 40 42 44 46 46 48 50 52 52 54 56 58 58 60 10 12 14 16 18 20 22 22 24 26 28 30 32 34 36 36 38 40 42 44 46 48 50 50 52 54 56 58 60 62 64 64 66 68 70 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 14 16 18 20 22 24 28 30 32 34 36 38 40 42 46 48 50 52 54 56 58 60 64 66 68 70 72 74 76 78 82 84 86 88 90 16 18 20 22 26 26 30 32 36 38 40 42 46 48 50 52 56 58 60 62 66 68 70 72 76 78 80 82 86 88 90 92 96 98 100 i l 1 16 20 22 24 28 30 34 36 38 42 44 46 50 52 56 58 60 64 66 68 72 74 78 80 82 86 88 90 94 96 100 102 104 108 110 18 22 24 28 30 34 36 40 42 46 48 52 54 58 60 64 66 70 72 76 78 82 84 88 90 94 96 100 102 106 108 112 114 118 120 i 20 22 26 30 32 36 40 42 46 48 52 56 58 62 66 68 72 74 78 82 84 88 92 94 98 100 104 108 110 114 118 120 124 126 130 { 22 24 28 32 36 38 42 46 50 52 56 60 64 66 70 74 78 80 84 88 92 94 98 102 106 108 112 116 120 122 126 130 134 136 140 '< 22 26 30 34 38 42 46 48 52 56 60 64 68 72 76 78 82 86 90 94 98 102 106 108 112 116 120 124 128 132 136 138 142 146 150 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 124 128 132 136 140 144 148 152 156 160 f 26 30 34 38 42 46 52 56 60 64 68 72 76 80 86 90 94 98 102 106 110 114 120 124 123 132 136 140 144 148 154 158 162 166 170 28 32 36 40 46 50 54 58 64 68 72 76 82 86 90 94 100 104 108 112 118 122 126 130 136 140 144 148 154 158 162 166 172 176 180 f C 28 34 38 42 48 52 58 62 66 72 76 80 86 90 96 100 104 110 114 118 124 128 134 138 142 148 152 156 162 166 172 176 180 186 190 9 30 36 40 46 50 56 60 66 70 76 80 86 90 96 100 106 110 116 120 126 130 136 140 146 150 156 160 166 170 176 180 186 190 196 200 10 32 36 42 48 52 58 64 68 74 78 84 90 94 100 106 110 116 120 126 132 136 142 148 152 158 162 168 174 178 184 190 194 200 204 210 1C 34 38 44 50 56 60 66 72 78 82 88 94 100 104 110 116 122 126 132 138 144 148 154 160 166 170 176 182 188 192 198 204 210 214 220 11 34 40 46 52 58 64 70 74 80 86 92 98 104 110 116 120 126 132 138 144 150 156 162 166 172 178 184 190 196 202 208 212 218 224 230 11 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 126 132 138 144 150 156 162 168 174 180 186 192 198 204 210 216 222 228 234 240 12 38 44 50 56 62 68 76 82 88 94 100 106 112 118 126 132 138 144 150 156 162 168 176 182 188 194 200 206 212 218 226 232 238 244 250 12 40 46 52 58 66 72 78 84 92 98 104 110 118 124 130 136 144 150 156 162 170 176 182 188 196 202 208 214 222 228 234 240 248 254 260 13 40 48 54 60 68 74 82 88 94 102 108 114 122 128 136 142 148 156 162 168 176 182 190 196 202 210 216 222 230 236 244 250 256 264 270 13 42 50 56 64 70 78 84 92 98 106 112 120 126 134 140 148 154 162 168 176 182 190 196 204 210 218 224 232 238 246 252 260 266 274 280 14 44 50 58 66 72 80 88 94 102 108 116 124 130 138 146 152 160 166 174 182 188 196 204 210 218 224 232 240 246 254 262 268 276 282 290 14 46 52 60 68 76 82 90 98 106 112 120 128 136 142 150 158 166 172 180 188 196 202 210 218 226 232 240 248 256 262 270 278 286 292 300 15 Zt'SO 6ZOS3 * AREA-SQUARE FEET THERMALUX AREA CALCULATOR H-2? U S G AREA CEILING HEIGHT--FT. 8 8/4 9 10 AREA CEILING HEIGHT -FT. 8 8/, 9 10 CEILING HEIGHT -FT. AREA 8 8/4 9 10 CEILING HEIGHT -FT. AREA 8 8 'A 9 10 CEILING HEIGHT -F AREA 8 8/4 9 1i 2 20 20 20 20 52 420 440 460 520 102 820 860 920 1020 152 1220 1300 1360 1520 202 1620 1720 1820 20 4 40 40 40 40 54 440 460 480 540 104 840 880 940 1040 154 1240 1300 1380 1540 204 1640 1740 1840 20 6 40 60 60 60 56 440 480 500 560 106 840 900 960 1060 156 1240 1320 1400 1560 206 1640 1760 1860 20 8 60 60 80 80 58 460 500 520 580 108 860 940 980 1080 158 1260 1340 1420 1580 208 1660 1760 1880 20 10 80 80 100 100 60 480 520 540 600 110 880 940 1000 1100 160 1280 1360 1440 1600 210 1680 1780 1900 21 12 100 100 100 120 62 500 520 560 620 112 900 960 1000 1120 162 1300 1380 1460 1620 212 1700 1800 1900 21 14 120 120 120 140 64 520 540 580 640 114 920 960 1020 1140 164 1320 1400 1480 1640 214 1720 1820 1920 21 16 120 140 140 160 66 520 560 600 660 116 920 980 1040 1160 166 1320 1420 1500 1660 216 1720 1840 1940 21 18 140 160 160 180 68 540 580 620 680 118 940 1000 1060 1180 168 1340 1420 1520 1680 218 1740 1860 1960 21 20 160 180 180 200 70 560 620 640 700 120 960 1020 1080 1200 170 1360 1440 1540 1700 220 1760 1880 1980 22 22 180 180 200 220 72 580 620 640 720 122 980 1040 1100 1220 172 1380 1460 1540 1720 222 1780 1880 2000 22 24 200 200 220 240 74 600 620 660 740 124 1000 1060 1120 1240 174 1400 1480 1560 1740 224 1800 1900 2020 22 26 200 220 240 260 76 600 640 680 760 126 1000 1080 1140 1260 176 1400 1500 1580 1760 226 1800 1920 2040 21 28 220 240 260 280 78 620 660 700 780 128 1020 1080 1160 1280 178 1420 1520 1600 1780 228 1820 1940 2060 21 30 240 260 280 300 80 640 680 720 800 130 1040 1100 1180 1300 180 1440 1540 1620 1800 230 1840 1960 2080 2; 32 260 280 280 320 82 660 700 740 820 132 1060 1120 1180 1320 182 1460 1540 1640 1820 232 1860 1980 2080 2: 34 280 280 300 340 84 680 720 760 840 134 1080 1140 1200 1340 184 1480 1560 1660 1840 234 1880 1980 2100 2: 36 280 300 320 360 86 680 740 780 860 136 1080 1160 1220 1360 186 1480 1580 1680 1860 236 1880 2000 2120 2: .38 300 320 340 380 88 700 740 800 880 138 1100 1180 1240 1380 188 1500 1600 1700 1880 238 1900 2020 2140 2 40 320 340 360 400 90 720 760 820 900 140 1120 1200 1260 1400 190 1520 1620 1720 1900 240 1920 2040 2160 2 42 340 360 380 420 92 740 780 820 920 142 1140 1200 1280 1420 192 1540 1640 1720 1920 242 1940 2060 2180 2 44 360 380 400 440 94 760 800 840 940 144 1160 1220 1300 1440 194 1560 1640 1740 1940 244 1960 2080 2200 2 46 360 400 420 460 96 760 820 860 960 146 1160 1240 1320 1460 196 1560 1660 1760 1960 246 1960 2100 2220 2 48 380 400 440 480 98 780 840 880 980 148 1180 1260 1340 1480 198 1580 1680 1780 1980 248 1980 2100 2240 2 50 400 420 460 500 100 800 860 900 1000 150 1200 1280 1360 1500 200 1600 1700 1800 2000 250 2000 2120 2260 2 EfSO 6S0aa volume-cubic feet THERMALUX VOLUME CALCULATOR H-2T u s a 7 /a4 Printed m CEILING A R E A -S Q U A R E FEET frfrso 6zoae HEAT LOSS-WATTS '.U,v 'TVV THERMALUX HEAT LOSS CALCULATOR CEILING HEAT LOSS FLOOR A R E A -S Q U A R E FEET 6Z093 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 HEAT LOSS-WATTS THERMALUX HEAT LOSS CALCULATOR FLOOR HEAT LOSS FLOOR A R E A -S Q U A R E FEET 9^50 63099 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 180C HEAT LOSS--WATTS THERMALLX HEAT LOSS CALCULATOR FLOOR HEAT LOSS H ROOM V O LU M E -C U B IC FEET 2400 2300 2200 2100 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 HEAT LOSS-WATTS THERMALUX HEAT LOSS CALCULATOR INFILTRATION HEAT LOSS OUTSIDE DESIGN TEMPERATURE 30 --20 --10 0 +10 +20 +30 POWER RATE 0.5c 1.0c 1.5c 2.0c 2.5c 3.0c 8^50 63099 DEGREE DAYS . THERMAL UX HEATING COST CALCULATOR H*-24 U.S.G. 7/64 ANNUAL OPERATING COSTS (PER KW HEAT LOSS) BASED ON NEMA OPERATING COST FORMULA WITH C-FACTOR OF 17 Printed in USA. CHAPTER 6 THERMALUX SYSTEM INSTALLATION NECESSARY CONSTRUCTION KNOWLEDGE Since the THERMALUX Heating System is basically a gypsum board ceiling, a knowledge of drywall con struction is necessary. However, since THER MALUX is also an electric heating unit, competence in electrical wiring and familiarity with the National Electrical Code and local electrical code is essen tial. can be installed on a common mounting board as shown in Figure 6-1. Control relays also may be placed in other locations, according to System De sign, to simplify wiring. HEATING BRANCH CIRCUIT RACEWAY (TO JUNCTION BOX) MATERIALS REQUIRED FOR INSTALLATION Chapter 2 of this Handbook fully describes the ma terials required for a complete THERMALUX Sys tem installation. Quantities of the required THER MALUX components will be readily determined from the System Design, prepared for each job on which THERMALUX is to be installed. System Designs are prepared in accordance with Chapter 5 of this Handbook. TOOLS REQUIRED FOR INSTALLATION The tools required to install, finish, and test the THERMALUX System are standard, familiar to contractors, and readily available. Necessary tools are: Straight edge Steel rule Trimming knife Wall board hammer Utility saw Circle cutter Rasp Rubber mallet Bit-brace with hole saw BOSTITCH T5-8gd stapling gun Roller for adhesive Electrician's pliers STA-KON WT-111 or WT119 terminal pliers Long-nose pliers Electric fish tape Drill-bit extension and electrician's drill-bit Test lamp Volt-Ohmmeter Ammeter Conduit bender Conduit cutter and reamer Joint finishing tools Screwdriver ELECTRICAL INSTALLATION Power Supply Figure 6-1. Installing The Power Supply Local code regulations must be followed when install ing heating branch circuits. The code will dictate the type of wiring to be used, such as electrical metallic tubing, flexible conduit, or armored cable. Since many localities require metallic raceways, much of the following discussion and many of the accompany ing illustrations will reference such systems. If local code permits the use of non-metallic cable, armored cable, or knob-and-tube wiring, the race ways may be ignored. However, wire connections and wire routing, as discussed and illustrated, will still apply; only the mechanics of installation, such as anchoring the wiring, will differ. The service drop, service entrance, and service box, when a THERMALUX System is installed, are essentially the same as required for any structure except that capacity must be increased. However, added branch wiring and thermostat-control circuits for the THERMALUX System are required. The System Design will dictate the required number of branch circuits, thermostats, and control relays to be installed. The service box and control relays The System Design will specify the choice of 2-wire or 3-wire circuits and the size of branch circuit con ductors. These design factors are based on the square footage of Heating Panel (which determines amperage) and current load for each circuit. Typical THERMALUX System wiring for 2-wire and 3-wire systems are shown in Figure 6-2. 6-1 BB029 0549 HOT 240V HOT 2-WIRE 5YSTEM 3-WIRE SYSTEM Figure 6-2. Typical THERMALUX Wiring Systems Control Circuits Two types of control relays may be used in a THER MALUX Heating System. The System Design will specify either a Type 705 or Type 706 for each of the branch circuits. Both work on the same principle with a Type 706 merely being two Type 705's in one enclosure. The Type 705 control relay, schematically illus trated in Figure 6-3, has one 22-amp switch which can control one branch circuit with a maximum 22amp load. One Type 820E thermostat is used in conjunction with this type control relay. The Type 706 control relay has two 22-amp switches, each of which can be controlled by individual 820E thermostats; thus having two separate branch cir cuits with individual control circuits, as shown in Figure 6-4. For reasons of installation economy, this method should be used, rather than using two Type 705 control relays, whenever possible. The Type 706 control relay can also be used with one 820E thermostat, as illustrated in Figure 6-5. This situation occurs where a large room requires two branch circuits to accommodate the current load required by the square footage of heating panels; yet it is desirable to control the temperature of the room with one thermostat. This situation could be covered using two Type 705 control relays but again, for economic reasons, the Type 706 should be used. To supplement the control relay and thermostat wiring instructions included here, the United States Gypsum Company has available, on request, individ ual brochures on each of the control relays and the thermostat recommended for use in a THERMALUX System. Line voltage thermostats can also be used with the THERMALUX Heating System. However, the de signer should recognize that such thermostats do not have the sensitivity and response characteristics to provide highest quality comfort control. Thermostat location must be in accordance with the System Design. Chapter 5 of this Handbook recom mends to the system designer that the thermostat be mounted on an inside wall, 36 to 60 inches above the floor. Be sure the location selected is away from heat sources such as lamps, a television set, fire place, or hot water pipes. Avoid cold area locations near windows, doors, or cold water pipes. Wiring, from the control relays to the thermostats, must comply with the National Electrical Code and local code requirements. 6-2 BB029 0550 TO TYPE 820E LOW VOLTAGE THERMOSTAT * SPLICE Figure 6-3. Type 705 Control Relay TO TWO TYPE 820E LOW VOLTAGE THERMOSTATS CONTROL RELAY \ f '2 * * 'I * I 1 i\/- 11 14V ` TO ONE TYPE 820E LOW VOLTAGE THERMOSTAT TO HEATER LOAD ('1 BRANCH CIRCUIT) WIRING RACEWAY TO HEATER LOAD ('2 BRANCH CIRCUIT) Figure 6-4. -------- INTERNAL WIRING ---------FIELD WIRING * SPLICE Type 706 Control Relay with Two Control Systems 6-3 TO HEATER LOAD (#2 BRANCH CIRCUIT) ------- INTERNAL WIRING --------FIELD WIRING SR SPLICE Figure 6-5. Type 706 Control Relay with One Control System BB029 0551 Branch Circuits and Junction Boxes Locate junction boxes in accordance with the Sys tem Design and install in an accessible position in compliance with Article 370-19 of the National Elec trical Code. Raceways/wiring between the power supply and junction boxes must comply with code re quirements and be installed in the structure in ac cordance with good electrical practice. Generally, the System Design permits some flexi bility in junction box location. However, they should be placed where readily accessible and as close as possible to the associated wiring recess. Attic space provides a convenient location for junc tion boxes. Locations near the center of the house, rather than under the eaves, are preferred. Con cealment of the boxes usually isn't necessary. Posi tion the junction box near the wiring recess, to shorten conductor runs and make them readily ac cessible so wiring connections can be inspected and tested. A wall is also a logical location for junction boxes although this position has two distinct disadvantages. First, additional wiring to the wiring recess will be required. Secondly, concealment of the junction box will be necessary. This can be accomplished by re cessing the box into the wall. However, the cover will be apparent so it is desirable to locate the junc tion box in an unobstrusive place such as a closet. desirable to install them prior to erecting the THER MALUX Panels. In fact, the panels themselves form at least one side of the recess while the Finishing Panels form the bottom of the recess. The System Design will designate the wire sizes to be accommodated in the recess. A good design will have a well balanced electrical system requiring the use of #10 and #12 wire only. These wire sizes require a re cess depth of only 1/4" if wires are not required to crossover, and a 1/2" deep recess if wires must crossover. A crossover will be required if more than two THERMALUX Panels are wired through the same recess. All recesses should be 3" to 6" wide. Nails used in constructing a recess should be of the insulated type. Wiring recesses may be constructed in a variety of ways. Several typical wiring recess construction methods are described and illustrated here but other, more applicable constructions, may be devised to suit design requirements. Heating Panels and Filler Panels, identified in the illustrations, are shown for reference only, indicating where they will be posi tioned when they are installed. The most important requirement in wiring recess construction is that wiring be completely surrounded by non-flammable, non-conductive gypsum. WIRING RECESS CONSTRUCTION FOR HEATING PANELS PERPENDICULAR TO JOISTS The least desirable junction box location is in the floor of the area above the THERMALUX Panels. Junction box location in close proximity to the wiring recess is easily attained but concealment of the junc tion box cover is only possible by covering it with a rug or carpeting. Figure 6-6 illustrates typical attic, wall, and floor junction box installations. 1/2" Deep Wiring Recess Construction (Figure 6-7) Locate, from the System Design, the pair of joists between which the wiring recess must be constructed. Nail 2" x 4" blocking 24" on centers between the joists for the length of the recess. The bottom of the blocking must be 1/2" above the lower face of the joists. The wiring from the junction boxes to the THER MALUX Panels, must be done after wiring recess construction and panel installation. Cut a piece of 1/2" gypsum board 6" wider than the proposed wiring recess width and the length of the recess. SUPPLEMENTARY THERMALUX PANEL FRAMING At times THERMALUX Heating Panels must be in stalled in positions that do not conform with the structure framing. When such installations are nec essary, supplementary framing will be required to firmly support the THERMALUX Panels. It is de sirable, in most instances, to install this framing prior to panel erection. Good construction practice should be followed when installing supplementary framing. WIRING RECESS CONSTRUCTION Align the centerline of the gypsum board with the headers and nail in place. This forms the top of the wiring recess, with the gypsum now at the same level as the joists, ready for Heating or Filler Panels to be installed. These panels will then form the sides of the wiring recess and give it a 1/2" depth. 1/2" Deep Wiring Recess Construction (Figure 6-8) Locate, from the System Design, the pair of joists between which the wiring recess must be constructed. Nail 2" x 2" wood strips along facing sides of the joists for the length of the recess. The bottom of the strips must be 1/2" above the lower face of the joists. BB029 0552 Wiring recesses must be installed in the locations indicated by the System Design. Because of the methods used in constructing the recesses, it is Cut a piece of 1/2" gypsum board the width of the space formed by the joists and the length of the pro posed recess. 6-4 CONTROL RELAY METALLIC RACEWAY Figure 6-6. Typical Attic, Wall, and Floor Junction Box Installations HEATING BRANCH CIRCUIT HEATING BRANCH RECESS Figure 6-7. Wiring Recess Construction (1/2" Depth) 6-5 OR FILLER PANEL Figure 6-8. Wiring Recess Construction (1/2" Depth) o NJ vo o Ln Ln u> Position the gypsum board against the 2" x 2" strips and nail in place. This forms the top of the wiring recess, with the gypsum board now at the same level as the joists, ready for Heating or Filler Panels to be installed. These panels will then form the sides of the wiring recess and give it a 1/2" depth. HEATING BRANCH CIRCUIT 1/2" Deep Wiring Recess Construction (Figure 6-9) This method of wiring recess construction is used after Heating and Filler Panels have been installed. However, this method is only practical where there are open joists on the floor above, such as an attic. Adequate space must also be available for this type installation as a length of 1/2" gypsum board, equal to the length of the proposed wiring recess and 6" to 8" wider than the proposed wiring recess width, must be handled. JOIST HEATING BRANCH CIRCUIT Figure 6-10. Wiring Recess Construction (1/4" Depth) edge of the headers must be flush with the bottom edge of the joists. Also, the top of the recess is cut from a 1/4" gypsum board and to the exact length and width of the recess. This piece is then nailed to the headers in the specified location and forms the top of the recess. Heating Panels, when installed, will abut the top board of the wiring recess, forming sides 1/4" deep. WIRING RECESS CONSTRUCTION FOR PANELS PARALLEL TO JOISTS Figure 6-9. Wiring Recess Construction (1/2" Depth) To use this method, cut a section of 1/2" gypsum board, as mentioned above, equal to the length of the proposed wiring recess and 6" to 8" wider than the proposed wiring recess width. Apply THERMALUX Adhesive, 3" to 4" wide, on one side of the gypsum board over its entire length, parallel to both edges. Apply THERMALUX Adhesive, in a strip 3" to 4" wide, to the top side of the installed Heating and/or Filler Panels, along the wiring recess opening left by these panels. When the THERMALUX Adhesive becomes non-tacky (20 to 30 minutes after application), position the 1/2" gypsum panel on the Heating and/or Filler Panels and over the wiring recess opening. This 1/2" gypsum board has now' become the top of the wiring recess and the Heating and/or Filler Panels form the sides, giving it a depth of 1/2". 1/4" Deep Wiring Recess Construction (Figure 6-10) To construct a 1/4" deep wiring recess, the method for a 1/2" deep recess applies except that the bottom 1/2" Deep Wiring Recess Construction (Figure 6-11) Locate, from the System Design, the exact position of the proposed wiring recess. Mark the wiring re cess location on the underside of the ceiling joists. Cut 2" x 2" (or larger) wood blocking strips approxi mately 4" longer than the wiring recess width. Nail the 2" x 2" blocking to the sides of each joist, par allel to and 1/2" from the bottom edge the joist, and centered above the area to be occupied by the wiring recess. Cut pieces of 1/2" gypsum board approximately 4" wider than the proposed wiring recess width and of a length equal to the spacing between joists. Nail these boards to the underside of the 2" x 2" blocking. These boards now become the top of the wiring re cess. However, the flammable joists are still ex posed in the recess. The exposed joists are covered by 1/4" gypsum boards cut to the exact width of the wiring recess and approximately 6" long. Center these across the joists, between the scribe marks, and nail them to the joists. This completes the top of the wiring re cess. When the Heating or Filler Panels are in stalled, abut them against the 1/4" gypsum board and overlapping the 1/2" gypsum board. These will form the 1/2" sides of the wiring recess. Note that in the joist areas, the wiring recess will only be 1/4" deep, necessitating required wiring crossovers to 6-6 BB029 0554 1/2" GYPSUM BOARD BETWEEN JOISTS HEATING BRANCH CIRCUIT 2" x 2" BLOCKING JOIST HEATING PANEL 1/2" WIRING RECESS FINISHING PANEL BUSHING 1/4" GYPSUM BOARD AT EACH JOIST PERF-A-TAPE GYPSUM WALL BOARD CORNER REINFORCEMENT Figure 6-11. Wiring Recess Construction (1/2" Depth) take place in the 1/2" deep areas. This type of wiring recess can be constructed adjacent to or away from a partition. wall plate. These boards now become the top of the wiring recess. However, the flammable joists are still exposed and must be covered with a strip of 1/4" gypsum board as described in Figure 6-11. Since the wiring recess will be only 1/4" deep at joist locations, any wiring crossovers must be made in the 1/2" deep recess between joists. 1/4" Deep Wiring Recess Construction (Figure 6-13) Locate, from the System Design, the exact position of the proposed wiring recess. Mark exact width of the wiring recess on the underside of the joists. Cut a piece of 1/4" gypsum board the exact length and width of the proposed wiring recess. Position on joists and nail in place. When installing Heating Panels, they must abut the 1/4" gypsum board, forming the 1/4" deep sides of the wiring recess. Only two Heating Panels can be serviced by this type wiring recess since the 1/4" depth will not permit cable crossovers. 1/2" Deep Wiring Recess Construction (Figure 6-12) Locate, from the System Design, the exact position of the proposed wiring recess. Mark the wiring re cess location on the underside of the ceiling joists. Cut 1" x 6" or 1" x 8" boards (depending on the width of the proposed wiring recesses) to a length equal to the spacing between joists. Cut 1/4" or 1/2" gypsum boards (optional) to the same length and approximate ly 2" wider than the 1" x 6" or 1" x 8" boards. Nail the gypsum boards to the wood boards, allowing a 1" overhang on each side. HEATING JOIST 1/2" WIRING RECESS HEATING PANEL HEATING BRANCH CIRCUIT 1" x 6" or 1" x 8" BUSHING WOOD BOARD BETWEEN JOISTS Figure 6-13. Wiring Recess Construction (1/4" Depth) FINISHING PANEL PERF-A-TAPE CORNER REINFORCEMENT 1/4" OR 1/2" GYPSUM BOARD GYPSUM WALL BOARD Figure 6-12. Wiring Recess Construction (1/2" Depth) Position these boards between the joists centered on the wiring recess location, with the face of the gypsum board flush with lower edge of the joists and nail to the Wiring Recess Construction when Abutting a Wall When a wiring recess is constructed adjacent to a wall or partition (such as illustrated in Figures 6-10, 6-11, 6-12 and 6-13), provision must be made so that the gypsum board on the sidewalls will complete ly isolate the combustible wood framing from the wiring. This is readily accomplished by temporarily nailing scrap pieces of 1/2" gypsum (or other thick ness equal to wall board thickness), to the wall studs and abutted against the ceiling joists before con structing the wiring recess. Following recess in stallation, remove the scrap pieces of gypsum. When installing gypsum board on side walls, insert the panels into the opening and abut the joists. Wiring Recess Closing Blocks After the top of the wiring recess has been installed, the ends also must be closed with gypsum board, to seal the recess from combustible material. Usually the Filler Panel installed in the ceiling will provide these closures. However, it is sometimes necessary to use separate strips of gypsum board for this pur pose. Install according to the following method. Cut a strip of scrap gypsum board the thickness of the recess, at least 1" wide, and as long as the recess is wide; nail the gypsum strip to the framing at each end of the recess to provide a safe clearance between recess and any framing. This strip is not necessary, as mentioned above, when the recess ends against Heating or Filler Panels. Wiring Recess Configuration The wiring recess should be designed to run in a straight line, for its full length, without turns or angles which complicate support blocking and con ductor fastening. Still, the recess must accommo date the heating panel layout. Therefore, "L"shaped, ''U"-shaped, and other simple continuous recess designs are frequently employed without diffi culty. A ,"U"-shaped recess is often used in hall ways to connect single heating panels on each side of a central light fixture as shown in Figure 6-14. Here, the Filler Panel is "step-shaped" providing closure of the wiring recess at the end of heating element. HEATING PANELS U-SHAPED (A-30-24.48) WIRING RECESS Nailing Always use THERMALUX Insulated Nails when in stalling Heating Panels. If standard nails were used, they would be electrically "hot" from contact ing the electrical element. The type A-60-48.48 panel has 1/2" electrodes run ning the entire length of the panel 1" in from, and parallel to, each edge. The electrode area is the only area through which nails must not be driven. The type A-30-24.48 has one electrode running the entire length of the panel 1" in from, and parallel to, one edge. The second electrode is then 22" from, and parallel to, the first electrode. Again, the elec trode area is the only area through which nails must not be driven. Cutting Heating Panels to Length Normally, the System Design will not require that Heating Panels be cut to length. However, both types of Heating Panels can be cut to length. It is essential, however, that the cut be made completely across the panel, perpendicular to the electrodes, as shown in Figure 6-15. LIGHT FIXTURE FILLER JUNCTION BOX PANEL Figure 6-14. Irregular Wiring Recess Construction Figure 6-15. Cutting Heating Panel by Scoring through Electrodes and Heating Element HEATING PANEL INSTALLATION Two types of Heating Panels are available, the A-6048.48 and the A-30-24.48. Panel construction of both types is shown in Figure 4-1. Heating Panel installa tion is as simple as regular gypsum board. The only precautions necessary, when installing Heating Panel, are in cutting and nailing. To cut a Heating Panel, simply score it on the ele ment side, using a sharp knife and a straight edge (Figure 6-15). The score must cut through the heat ing element, electrodes and paper on the gypsum panel. Snap the panel at the score mark by exerting a slight downward pressure as shown in Figure 6-16. Smooth and square the cut edge with a rasp or sand- paper. 6-8 Co kj O in CTl Figure 6-16. Snapping Heating Panel on Scored Mark Cutting Heating Panels to an Irregular Length Heating Panels may be cut to an irregular length when necessary to fit an unusual structural condi tion. However, this should be avoided whenever possible since heating area is lost and additional work is entailed. A System Design will seldom re quire this be done. If such a cut is necessary, mark the shape of the cut on the panel as shown in Figure 6-17. SCORE ENTIRE WIDTH Cutting Heating Panels to Width Only panel type A-30-24.48 can be cut to width. This panel is constructed with a 22" heating element, leaving a 24" trim width, as shown in Figure 4-1. This trim area, which is not covered with heating elements is used to reduce panel width. However, the panel must not be trimmed narrower than 24" as that would separate the electrodes, creating an open circuit. Accommodating Light Fixture Junction Boxes and Other Devices in Heating Panel Areas Normally, good System Design will locate light fix tures in a Filler Panel area, with the required dis tance of 7" from the adjacent Heating Panel edge or 8" from the end as shown in Figure 6-18. It is not always possible to position Filler Panel for light fixtures so then they have to be accommodated in Heating Panel areas. HEATING PANEL HEATING PANELS FILLER Figure 6-17. Cutting Heating Panel with Irregular Shaped End to Length Score the Heating Panel, on the element side, straight across as shown in Figures 6-15 and 6-17. The score must be made at the point where the deepest irregu larity of the end cut occurs and to a depth which in sures severing the heating element and electrodes. The panel must be scored again with about 1/4" be tween cuts. Then the heating element and electrodes must be removed from the 1/4" area so that electrical continuity of the panel is broken. The irregularly shaped end may now be cut. Figure 6-18. Light Fixture Junction Boxes Adjacent to Heating Panels All cutouts of Heating Panels must be made Ln accord ance with the System Design and the following limita tions . Heating Panels 8' or less in length can only have one cutout. Panels 8' or longer in length will accommo date two cutouts. Edges of cutouts must be at least 6-9 BB029 0557 6" from panel ends, 2" from electrodes. If two cut outs are made in the same panel, they must be at least 24" apart. All edges of cutouts must be at least 8" from the light fixture junction box. Edges of the Heating Panel must be at least 2" from metal pipes or ducts. The shape of the cutouts may be circular or square. However, corners of square cutouts must have a radius 2" or larger. Pertinent cutout dimensions are illustrated in Figure 6-19, as are the panel areas in which heat loss will occur because of the cutouts. Heating Panel-to-Wall Isolation Where ends of Heating Panels are extended to a wall, two methods of isolation may be used. The first method, which takes place during installation, is to temporarily nail a strip of 1/2" scrap gypsum board across the studs, abutted against the ceiling joists, at the Heating Panel wall junction. When installing the Heating Panel, butt the ends snugly against the 1/2" scrap board, then remove the scrap board. When 1/2" gypsum wall board is subsequently in stalled, slip it into the 1/2" opening and butt it firm- VENT DUCT \ 2" MIN. Figure 6-19. Typical Cutouts Made in a Heating Panel Cross-bracing must be installed behind a Heating Panel cutout to provide nailing accommodations for the Heating Panel and the Filler Panel plug which must be fitted into the cutout. The method for in stalling cross-bracing is illustrated in Figure 6-20. Heating Panel Isolation Particular attention must be given to ascertain that all panel heating elements and electrodes are isolated from metal and/or combustible materials. A study of the System Design will indicate where Heating Panels will terminate. Only panel ends must be con sidered since panel edges have 1" wide areas beyond the electrodes which do not contain heating element. Panel ends abutting wiring recesses, of course, need not be considered. Panels abutting Filler Panels present no problem since Filler Panels are nonconductive and non-flammable. ly against the ceiling joists. This method is illus trated in Figure 6-21. An alternate method is to remove 2" of heating ele ment and electrodes from the end of the Heating Panel prior to installation. Heating Panel External Corner Isolation Heating Panels installed with ends adjacent to stair wells, hatchways, skylights, and soffits usually be come part of external corners. In such instances isolation takes place during installation. The gypsum board installed in the vertical plane, as shown in Figure 6-22, must be at least 1/2" thick and cover edges of both the Heating Panel and Finishing Panel. PERF-A-BEAD* corner reinforcement is used to enclose the joint. *T. M. Reg. U. S. Pat. Off. BB029 0558 6-10 LIGHT FIXTURE JUNCTION BOX METAL HANGER SUPPORTING JUNCTION BOX GYPSUM BOARD Figure 6-20. Typical Cross-Bracing for a Heating Panel Cutout 2" x 4" BLOCKING CEILING JOIST Figure 6-22. Isolating Heating Panel which Becomes Part of an External Corner in the Heating Panel. Damage to the heating element could cause "arcing" or possible "dead areas" in the panel. When nailing Heating Panels in position, be sure to observe the precautions outlined earlier in this chap ter under "Nailing". Nails should be spaced 10" c-to-c and follow each joist and supplementary frame covered by the panel as shown in Figure 6-23. Figure 6-21. Isolating Heating Panel which Abuts a Wall Figure 6-23. Installing Heating Panels Heating Panel Erection Actual installation of the Heating Panels is simple once the electrical wiring, supplementary structure framing, wiring recesses, necessary insulation, and panel cutting have been accomplished. Filler Panel Erection Filler Panels require no special installation instruc tions. Standard practice, as used when installing any gypsum board, is the only requirement. It is re commended that Insulated Nails be used 10" c-to-c, as with Heating Panels. Inspect each Heating Panel before installation to be sure no cracks or gouges exist in the heating element. Damage to electrodes could cause large "dead areas" Remember that Filler Panel must be used in the m Heating Panel junction box cutouts. The simplest g way to cut a correct size piece is to use the piece w 6-11 o on on VD which was cut out of the Heating Panel as a template as shown in Figure 6-24. When cutting the Filler Panel to the shape of the template, cut on an angle as shown in Figure 6-24. Install the Filler Panel in the Heating Panel with the smaller diameter up, the larger diameter down, for an easy, yet snug fit. FILLER BOARD HEATING PANEL PIECE WHICH HAD BEEN CUT OUT RIGID CONDUIT DIRECTION OF BEVELED CUT HEATING PANEL PIECE USED AS TEMPLATE Figure 6-24. Cutting Filler Panel Plugs for Heating Panel FEEDER WIRING INSTALLATION The National Electrical Code, as well as local code, must be adhered to when completing the THERMALUX System wiring. In the "Electrical Installation" section of this chapter, system wiring was completed from power source through branch circuits to junc tion boxes located in close proximity to wiring re cesses. Wiring must now be completed from the junction boxes, into the wiring recesses, to the heat ing panels. Entry into the wiring recess is accomplished through a THERMALUX Bushing, a standard bushed end fit ting, or simply through drilled holes in the top board of the wiring recess. (Local code will determine whether the entry must be bushed.) Figure 6-25 illustrates the methods of entry into the wiring re cess. Refer to the System Design to determine wire size and type of raceway to be used. This, and local code, will determine whether a hole be drilled in the wiring recess to accommodate a THERMALUX Bush ing, bushed end fitting, or individual UF cables. Usual entry into the wiring recess is accomplished by using a hole saw of the appropriate size, as shown in Figure 6-26. The THERMALUX Bushing will accommodate all raceway systems, such as electrical metallic tubing, 6-12 FLEXIBLE CONDUIT 2-SCREW CONNECTOR GYPSUM BOARD WIRING RECESS BUSHED END FITTING UF CABLE Figure 6-25, Wiring Recess Entry Methods Figure 6-26. Drilling Wiring Recess for THERMALUX Bushing BB029 0560 rigid conduit, armored cable, flexible conduit, and non-metallic sheathed cable, when used with appro priate connectors. Ordinary UF cable may also enter the wiring recess through a THERMALUX Bushing. Bushed end fittings also accommodate all types of raceway systems. Therefore, the following installation instructions are applicable to both types of bushing entrys. The only special requirement for a bushed end fitting is that it be installed flush, and not protrude into the wiring recess, as shown in Fig ure 6-25. The following instructions also apply to direct entry of UF cable alone, as illustrated in Fig ure 6-25, or UF cable, sheathed in flexible nonmetallic tubing, entering the wiring recess through a single drilled hole. Appropriate Type UF conductors and raceways, as dictated by the System Design, are connected at the junction box. The raceway is connected to the THERMALUX Bushing which, in turn, is attached to the wiring recess with pan head sheet metal screws, as illustrated in Figure 6-27. Run the UF cable to the electrodes of the nearest Heating Panel, cut to length, and strip the conductor ends. 2. Fasten electrode connectors to the heating panels as shown in the following installation pictures: `X ' * BU- - 1 Figure 6-28. Slitting Face Paper To Free Electrode Strip Figure 6-28 Make 1/8-inch deep cut through face paper into the gypsum core. Cut parallel to the outside edge of the electrode strip, about three inches, starting at end of board. Figure 6-27. Attachment Of THERMALUX Bushing An electrode connector must now be attached to each of the two conductors on each heating panel. The following technique gets the best connection and is also the easiest and quickest method: 1. Have all component parts and tools at the job when it begins: a sharp knife, channel locks, STA-KON WT-111 or WT-119 terminal pliers, THERMALUX connectors. Check the original heating panel design. If actual installation differs from the heating panel layout as designed, be sure wire sizes used are ample to carry the load as hooked up. Figure 6-29. Peeling Back Paper Containing Electrode Strip Figure 6-29 Using knife, lift corner of face paper containing the electrode strip (location identified by red printed stripe) and face paper encasing it from the core of the board. Lifting element and electrode between plies of paper prevents ripping the electrode strip from the element or tearing the element from the board. Peel corner back far enough to fit the electrode connector on the electrode without tearing the element. 6-13 BB029 0561 Figure 6-32 Connector points, having pierced the electrode, come out through holes on op posite side of connector and are bent over with the round side of pliers to lock the connector onto the heating panel. Additional contact is made by 8 short contact points on inside of the connector. Figure 6-30. Attaching Electrode Connector Clip To Electrode Strip In Heating Panel Figure 6-30 V-base of electrode connector is being fitted over the heating element at the electrode strip. Figure 6-33. Inserting Feeder Conductor Into Electrode Connector Figure 6-33 Insert proper size conductor into the barrel of THERMALUX connector. Bend conductors at right angles to allow complete flexibility when making connections. Figure 6-31. Pressing Electrode Connector Clip Points Through Electrode Strip For Positive Contact Figure 6-31 STA-KON WT-111 pliers being used to squeeze the V-base of the electrode connector together, forcing the three prongs to pierce the electrode strip, making an electri cal connection. Figure 6-34. Clamping Conductor Into Clip For Positive And Permanent Contact. Figure 6-32. Bending Over Points For Permanent Hold 6-14 Figure 6-34 Place the lug located next to cut ting jaws of STA-KON WT-111 against the small flap on the electrode connector and squeeze. The lug indents the electrode con nector sufficiently to make a tight connection. Connectors must be tight to prevent arcing or burnout due to a loose connection. BB029 0562 Feeder conductors must be installed between the initially wired Heating Panel and adjacent panels being serviced by the same wiring recess. Simply cut appropriate lengths of Type UF conductor and attach Electrode Connectors to both conductors and heating elements as mentioned above. Make connec tions in accordance with Figure 6-36 and staple con ductors to the top of the wiring recess. Note that adjacent electrodes of side-by-side Heating Panels are at the same electrical potential. That means that adjacent panels are always connected in reverse polarity. Regardless of the number of panels serviced from a single branch circuit, all must be connected in this manner for reasons of safety. Since Heating Panels do not have a specific electrode "po larity", the same results can be obtained by revers ing all panel connections. Figure 6-35. Stapling Conductor To Wiring Recess Figure 6-35 Staple conductors into the wiring recess. PANEL 6-15 cn w HEATING SYSTEM TESTING AND INSPECTION Branch Circuit Resistance Tests A volt-ohmmeter is used to make branch circuit re sistance tests before power is applied to the THERMALUX System. Check the resistance between each black or red (hot) branch circuit conductor and its associated white (neutral) conductor as shown in Figure 6-37. (Note that two tests are required for a Type 706 control relay servicing two branch cir cuits, whether from a 2-wire or 3-wire system.) The measured resistance in ohms for each test, as explained in Chapter 4 of this Handbook, should equal 960 divided by the active square-foot area of the Heating Panel load on the circuit. R _ 960 Sq. Ft. Heating Panel on Circuit Resistance-test tolerance is subject to instrument accuracy but should be within 10% of the calculation. A very low reading (less than 85% of the calculated resistance) indicates a short circuit. A high reading (more than 115% of the calculated resistance) indi cates a damaged heating panel or a poor electrical connection. A reading in excess of 250,000 ohms indicates an open branch circuit conductor or open THERMALUX feeder cable. ------------- INTERNAL WIRING ----------- FIELD WIRING B SPLICE ' Continuous Operating Test A 24-hour continuous operating test is required be fore the Heating Panels and recesses may be en closed. Connect each pair of thermostat conductors together to permit continuous operation. Check the load-current in each branch circuit con ductor of the heating system at least three times during the 24-hour test period. Record the readings for the local inspector. Load-current readings can best be made by means of a clamp-on ammeter. The branch circuit conductors in the rectangular race way, illustrated in Figure 6-1, are easily accessible for these measurements. I = 0.125 x Sq. Ft. of Heating Panel on Circuit. A significant change in load current of any branch circuit during the continuous operating test indicates an open or a short circuit. To locate an open or shorted heating panel, discon nect the ground side of each panel, one at a time, and measure the resistance of the panel while it is disconnected. To locate an open or shorted wire, disconnect both ends of each wire, one at a time, and measure the TYPE 705 Figure 6-37. Testing Branch Circuit Resistance 6-16 ---------- INTERNAL WIRING ---------- FIELD WIRING B SPLICE CO % to OcOn' resistance of each wire while it is disconnected. Re place damaged heating panels or wiring. wiring. A typical humidistat installation is shown in Figure 6-38. Inspection Inspection is required after the 24-hour test has been completed. Make a thorough inspection of the entire THERMALUX System to be sure all code require ments have been met prior to the local inspectors arrival. The inspector may require that thermostats and humidistat (if used) be installed prior to his inspec tion of the structures complete electrical circuitry, lighting, power, and THERMALUX Heating System. All circuitry must be in compliance with local elec trical code requirements. If the inspector requires thermostats to be installed, they, of course, must be removed after inspection to permit remaining work such as wallboard and Finishing Panel erection, to be completed in the structure. Insulation Resistance Tests Figure 6-38. Typical Exhaust Fan/Humidistat Installation A volt-ohmmeter is used to make an insulation re sistance test after the THERMALUX System instal lation is complete. Turn off THERMALUX System power at the service box and disconnect all THER MALUX System neutral conductors in the service box to eliminate system ground returns. Measure the resistance between each THERMALUX System branch circuit conductor and ground. This can be conveniently accomplished at the control relay while manually holding the relay closed. Do not touch ex posed electrical connections as body resistance will upset readings. Branch-circuit conductors no larger than #12 must show a minimum insulation resistance of 1,000,000 ohms. A minimum insulation resistance of 250, 000 ohms is required for #10 conductors to comply with the requirements of Article 110-19(a) of the National Electrical Code. Reconnect the neutral conductors in the service box after insulation resistance tests have been completed. Final Inspection The exhaust fan can be wired to the junction box supplying power for the lighting circuit, and the humidistat can be wired to the same junction box. Since the humidistat functions as an automatic switch, it can be paralleled by a manual switch to permit manual control of the exhaust-fan. FINISH PANEL INSTALLATION Prior to installing THERMALUX Finish Panels, walls must be installed. Make certain that, in in stallations where wallboard is used to isolate Heat ing Panels and wiring recesses, the wallboard is in serted into the area between panels and wall studs and is tightly abutted against ceiling joists. Finish Panels are installed perpendicular-to Heat ing and Filler Panels with Finish Panel joints staggered to provide a uniform surface. Using the System Design and structure plans as a guide, pre cut Finish Panels as necessary. A final inspection may be required after all work has been completed in the structure. This is the option of the local inspector. EXHAUST FAN AND HUMIDISTAT INSTALLATION Although not a part of a THERMALUX System, an exhaust fan, automatically controlled by a humidistat, may be a requirement of the System Design. Instal lation at this stage of system completion, prior to erecting wall panels and Finishing Panel is, of ' course, desirable. The wiring for an exhaust fan and humidistat is in stalled as part of the general lighting and power Proper Lamination Methods . Pre-plan work and secure proper tools. Best ad hesive application results are obtained with a 3" diameter, 12" or 18" wide long-handled roller. Use medium-napped Pronel or lamb's wool roller cover with core that is not affected by organic solvents (Phenolic core works fine). Use adhesive pan with cover. Figure 6-39 shows how one contractor has prepared for lamination. THERMALUX Adhesive and Solvent are highly flam mable and toxic. Keep away from heat and flame. No smoking. Ventilate the job. Inform all trades 50 on the job of these precautions to prevent accidents. Remove empty or partially empty cans from the job. 6-17 29 0565 Figure 6-40. Rolling THERMALUX Adhesive Onto Back Of Special THERMALUX Finish Panels Figure 6-39. Providing For Plenty Of Ventilation Before Working With THERMALUX Adhesive or THERMALUX Solvent * THERMALUX Adhesive is specially formulated to tolerate heat of the panels. There can be no sub stitute of adhesives if job is to be satisfactory. Do not thin adhesive. THERMALUX Solvent is to be used only for clean-up, never for thinning adhesive. If adhesive in pan thickens, add more from can to regain working consistency. Energize and operate THERMALUX system for 24 hours. Then shut it off for one-half hour before applying adhesive to heating panels for face layer lamination. If building is properly enclosed, ceiling, face panels and adhesive will be above che 50F minimum temperature necessary for a satisfactory job. Adhesive Drying Time Important Allow adhesive on face panels and ceiling to dry for approximately 15 minutes before attempting lami nation. Proper laminating conditions exist when finish panel adhesive is sticky, rather than wet. to the touch (Figure 6-42). Adhesive should not trans fer to the fingers, yet still be quite sticky. Check several areas of panel but avoid roller lap marks where there is greater adhesive build-up. Condition of finish panels is the key. Laminate panels in the order in which they were coated, checking each to be sure adhesive has reached proper consistency. High humidity and low temperature conditions will add to the 15-minute approximate time required for proper adhesive condition; high temperatures and low humidity will reduce the time. Cut and fit all finish board before applying THERMALUX adhesive. Apply adhesive to back of THERMALUX finish panels, first (Figure 6-40). then coat heating panels and filler board previously erected on the ceiling (Figure 6-41). Coat only that area which can be laminated in 15 to 20 minutes: i.e., 3 to 5 panels. Stand finish panels on edge around the room to dry adhesive. Uniform adhesive application is important to get even drying. One gallon laminates about 150 sq. ft. of finished ceiling area. Stretching coverage beyond this invites bond failure. (Let roller sit submerged in adhesive when not in use to prevent hardening of roller cover. Roller covers with dried adhesive on them should not be used.) Figure 6-41. Rolling Adhesive Onto Installed Heating Panels 6-18 BB029 0566 Figure 6-42. Testing dryness of adhesive to be cer tain it is sticky, but not wet,when finish panels are adhered. Similar test on adhesive-coated finish panels governs time that lamination takes place. Adhesion Finish panels should be installed perpendicular to heating panels whenever possible. If room layout requires parallel lamination, finish panel joints should fall between heating panel joints. Adhesive bond is instant and panels cannot be shifted after contact. Position edge or end of finish panel against abutting wall or adjacent panel (Figure 6-43) and ''hinge" the panel into full contact by working toward the free edges (Figure 6-44). To avoid poor bond or sag, panels must be applied flat without trapped bubbles or bulges, and should not be forced into place. Figure 6-44. Smoothing Panel Into Preliminary Lamination Impact immediately with a 2-lb. half hard rubber mallet with 2-1/2 in. diameter flat face. Strike with mallet head flat to avoid indentations, and do not use wooden blocks. Impact directly under joists a minimum of once per lineal foot. Then impact be tween joists once per square foot (Figure 6-45). Do not impact over wiring recess or closer than six inches from that recess. Impacting must be done within five minutes of lamination: Rolling the entire ceiling with a long-handled roller is strongly recommended as follow-up procedure (Figure 6-46). It improves contact between layers. Figure 6-43. Laminating A Panel Beginning At One Edge, From Which It Is "Hinged" Into Place. With Contact Adhesive, Panel Cannot Be Moved Once The Two Surfaces Have Touched. 6-19 vCjl this practice can be joint deformation which appears later. Figure 6-46. Pressure Rolling To Further Assure Complete Lamination SPECIAL PRECAUTIONS TO TAKE WHEN LAMI NATING IN COLDER WEATHER - ANYTHING BELOW 50 . _ 1. House must be completely closed in and in sulated. The ceiling must operate continuous ly for a 24-hour period to warm the building and dry out panels. 2. A salamander can be used to warm the build ing and materials, providing it does not de posit soot on heating or finish panels. Before ap-lying the adhesive, cut salamander off, open windows to get a good cross draft and apply the adhesive. Once you have finished applying the adhesive, close windows and con tinue the operation. Heat can be turned on immediately after lamination to provide con struction heat and proper temperatures for applying the THERMALUX Joint Compound. De-energize ceiling one-half hour before painting, and do not paint while heating system is operating. If the ceiling has not been heating, raise its temper ature and air temperature to at least 50F before painting. After normal drying time for each coat of paint, ceiling temperature may be set as desired for comfort. Spray-on simulated acoustic finishes can be used for decoration but all materials on the market for this purpose reduce heat flow from the ceiling and thus increase the temperature of the heating element. According to scientific test results, 1/8-inch of sim ulated acoustic material: (1) raised temperature of face, back and within core of panel 5% above identical panel without simulated acoustic finish; (2) had 9% greater KWH power consumption; (3) had 23% longer heat-up time from 58 to 72F; and (4) doubled the thermostat cycle. Painting the THERMALUX Ceiling Normal paint procedures are employed with latex base paints recommended. TEXOLITE* primersealer followed by GRAND PRIZE* paint provides the most durable and washable of ceiling decorations. FINISHING THE JOB Prepare ceiling for finishing by carefully trimming damaged edges and ends of Finish Panels. When removing damaged edges, handle knife carefully to avoid cutting into heating element or electrode strip. In Figure 6-47, the knife is held in such a way that it cannot cut into the heating panels. Figure 6-47. Incising A Damaged Finish Panel Edge. Extreme Care Must Be Exercised To Avoid Cutting Through Finish Panel And Into Heating Element. Because this is a heated ceiling, THERMALUX PERF-A-TAPE ready-mlx joint compound must be used for satisfactory results. De-energize ceiling one-half hour before joint treat ment begins. Follow normal taping procedures (Fig ures 6-48, 6-49, 6-50). Wait at least two hours after joint treatment before again turning on heat,and then do so gradually, setting thermostat first at 60F and raising it 5 per day. The penalty of ignoring Since methods and conditions of application and use are beyond the control of the United States Gypsum Company, its warranties of FITNESS and MER CHANTABILITY' as well as any other warranties, expressed or implied, made in connection with the sale of this product, SHALL NOT BE EFFECTIVE OR ACTIONABLE UNLESS the product is applied according to United States Gypsum Company's direc tions and specifications. 6-20 BB029 0568 Figure 6-48. Joint Taping Finish Panel In Normal Manner With Materials Recommended Figure e6-s-On . To__p_p.ing TJo.in.t TIn Finish ,,Pane.l Figure 6-49. Finishing Corner 6-21 & oto vO o O' & CHAPTER 7 REFERENCE DATA Table 7-1. Climatic Data -- U. S. Cities* Table 7-1. Climatic Data -- U. S. Cities* (Cont) Location Total Yearly Degree Days Outside Design Temp. F. Location Total Yearly Degree Days Outside Design Temp. F. ALABAMA Anniston Birmingham Mobile Montgomery ARIZONA Flagstaff Phoenix Yuma ARKANSAS Bentonville Fort Smith Little Rock CALIFORNIA Eureka Fresno Independence Los Angeles Needles Point Reyes Red Bluff Sacramento San Diego San Francisco San Jose COLORADO Denver Durango Grand Junction Leadville Pueblo CONNECTICUT Hartford New Haven D.C. Washington FLORIDA Apalachicola Jacksonville Key West 2820 2780 1529 1954 7525 1492 951 4036 3188 2982 4632 2532 3834 1451 1495 4474 2546 2600 1574 3069 2410 5673 7143 5796 10678 5709 6139 6026 4258 1307 1113 77 12 12 22 18 -4 36 38 -1 6 8 32 32 12 41 30 43 37 38 -12 -6 -3 -9 -14 -2 0 10 28 53 Miami Pensacola Tampa GEORGIA Atlanta Augusta Macon Savannah Thomasville IDAHO Boise Lewiston Pocatello ILLINOIS Cairo Chicago Peoria Springfield INDIANA Evansville Fort Wayne Indianapolis Royal Center Terre Haute IOWA Charles City Davenport Des Moines Dubuque Keokuk Sioux City KANSAS Concordia Dodge City Iola Topeka Wichita KENTUCKY Lexington Louisville 7-1 173 1453 674 2811 2138 2049 1710 1513 5890 5483 6976 3756 6310 6087 5225 4360 6287 5134 6239 5366 7504 6091 6274 7271 5663 7012 5323 5058 4616 4919 4571 4979 4279 24 36 11 20 20 24 -10 -12 -17 0 -11 -13 -4 -7 -8 -6 -21 -12 -13 -15 -13 -16 -11 -9 -7 -8 -6 a -69 o _9 tO o tn -j o Table 7-1. Climatic Data -- U. S. Cities* (Cont) Table 7-1. Climatic Data -- U. S. Cities* (Cont) Location Total Yearly Degree Days Outside Design Temp. F. Location Total Yearly Degree Days Outside Design Temp. F LOUISIANA New Orleans Shreveport MAINE Eastport Greenville Portland MARYLAND Baltimore MASSACHUSETTS Boston Fitchburg Nantucket MICHIGAN Alpena Detroit Escanaba Grand Rapids Houghton Lansing Ludington Marquette Sault Ste. Marie MINNESOTA Duluth Minneapolis Moorhead St. Paul MISSISSIPPI Corinth Meridian Vicksburg MISSOURI Columbia Hannibal Kansas City St. Louis Springfield MONTANA Billings Havre Helena Kalispell Miles City 1175 2117 8246 9439 7681 4203 5791 6743 6102 8073 6404 8657 6474 9030 6982 7458 8529 9475 9574 7853 9327 7804 3087 2333 2000 5113 5393 4888 4469 4693 7106 8213 8126 8055 7850 26 14 -9 -9 8 0 -10 -4 -18 -4 -18 -8 -7 -16 -19 -27 -23 -29 -23 6 14 15 -9 -12 -8 -5 -5 -31 -39 -39 -31 -35 Missoula NEBRASKA Drexel Lincoln North Platte Omaha Valentine NEVADA Reno Winnemuca Tonopah NEW HAMPSHIRE Concord NEW JERSEY Atlantic City Cape May Newark Sandy Hook Trenton NEW MEXICO Albuquerque Roswell Santa Fe NEW YORK Albany Binghamton Buffalo Canton Ithaca New York Oswego Rochester Syracuse NORTH CAROLINA Asheville Charlotte Hatteras Manteo Raleigh Wilmington NORTH DAKOTA Bismarck Devils Lake Grand Forks Williston 7-2 7873 6611 5865 6546 6160 7075 6036 6369 5813 7612 4741 4870 5252 5369 5068 4389 3424 6123 6319 6556 6838 8305 6914 5050 6975 6863 6520 4072 3205 2392 3109 3075 2323 9033 9940 9871 9068 -15 -15 -17 -21 3 -9 -11 8 2 8 4 3 -9 -7 -5 -22 -4 5 -7 -4 -10 5 14 21 14 20 -31 -32 -31 -35 Table 7-1. Climatic Data -- U. S. Cities* (Cont) Table 7-1. Climatic Data -- U. S. Cities* (Cont) Location Total Yearly Degree Days Outside Design Temp. F. Location Total Yearly Degree Days Outside Design Temp. F. OHIO Cincinnati Cleveland Columbus Dayton Sandusky Toledo OKLAHOMA Broken Arrow Oklahoma City OREGON Baker Medford Portland Roseburg PENNSYLVANIA Erie Harrisburg Philadelphia Pittsburgh Reading Scranton ~ RHODE ISLAND Block Island Narragansett Pier Providence SOUTH CAROLINA Charleston Columbia Due West Greenville SOUTH DAKOTA Huron Pierre Rapid City TENNESSEE Chattanooga Knoxville Memphis Nashville TEXAS Abilene Amarillo Austin Brownsville Corpus Christ 4532 5717 5277 5597 5859 6394 3826 3519 7087 4547 4143 4122 6116 5258 4523 5048 5060 6047 5843 6397 5607 1769 2284 2890 3060 7902 7283 7535 3384 3590 3006 3513 2657 4345 1713 617 1011 -3 -5 -3 -4 -4 -5 -1 -14 10 19 -3 4 6 -3 3 -2 7 1 22 19 -21 -22 -22 8 5 6 3 7 -2 23 Dallas Del Rio El Paso Fort Worth Galveston Houston Palestine Port Arthur San Antonio Taylor UTAH Modena Salt Lake City VERMONT Burlington Northfield VIRGINIA Cape Henry Lynchburg Norfolk Richmond Wytheville WASHINGTON North Head L.H. Reservation Seattle Spokane Tacoma Tatoosh Island Walla Walla Yakima WEST VIRGINIA Elkins Parkersburg WISCONSIN Green Bay La Crosse Madison Milwaukee Wausau WYOMING Cheyenne Lander Yellowstone Park 2272 1407 2641 2361 1211 1276 1980 1340 1579 1909 6598 5463 7865 8718 3307 4153 3119 3720 5103 5211 4438 6852 4866 5724 4848 5845 5773 4750 8259 7650 7300 6944 8494 7562 8303 9605 8 20 * 8 23 19 11 20 19 12 -1 -17 -19 17 11 15 11 3 15 -16 15 18 . _12 -4 -1 -20 -20 -19 -17 -19 -30 -34 Extracted from 1963 and 1964 ASHRAE Guide and g Data books. 7-3 Uol 7-4 9000 10.000 Figure 7-1. Norm al Number of Degree-Days per Year 0 6Z0H9 Figure 7-2. Isotherms of Winter Outdoor Design Temperatures USING TABLE 7-2 Notice that the resistance R ol any material is shown in either of two columns, the first headed 1/k, the second 1/C. The first is for a 1" thickness of a homogeneous material. Multiply this fig ure by 2 to find the R for a 2" thickness of the material, by 3 for a 3" thickness, and so on. Where the R value is given in the second column, it is the resistance of the specific thickness of the material shown. To find the R of a thickness not shown in the table, multiply the R given for a specific thickness by the ratio of the thickness not shown to the thickness shown. For example, the R of 1/2" impregnated sheathing is 1.32. To find the R of 3/4" impregnated sheathing, multiply 1.32 by the ratio of 3/4 to 1/2. R = T75 x i '32 = 15 x 1-32 = 198 Material AIR SPACES Table 7-2. Thermal Properties of Building Materials* i For Heat Loss in Watts For Heat Loss in BTUH Description Conduc tivity (k) Note 1 Conduct ance (C) Note 2 Resistance (R) Per inch thickness (1/k) Note 1 For thick ness listed (1/C) Note 2 Conduc tivity (k) Note 3 Conduct ance (C) Resistance (R) Per inch For thick thickness ness listed (1/k) (1/C) Note 4 . Note 3 Note 4 Position Horizontal Horizontal Horizontal Horizontal Horizontal Sloping (45) Vertical Heat Flow Thickness Up 3/4-4 in. Down 3/4 in. Down 1-1/2 in. Down 4 in. Down 8 in. Up 3/4-4 in. Horizontal 3/4-4 in. - - - 0.3457 0.2871 0.2549 0.2373 0.2344 0.3252 0.3018 - _ - - - " 2.901 3.481 3.925 4.198 4.266 3.072 3.311 - - - " 1.18 0.98 0.87 0.81 0.80 1.11 1.03 - - - - 0.85 1.02 1.15 1.23 1.25 0.90 0.97 AIR SURFACES (Still Air) (15 mph Wind) Position Heat Flow Horizontal Up Sloping (45) Up Vertical Horizontal Slopbig (45) Down Horizontal Down Any position - any direction _ - - BUILDING Asbestos-cement board BOARD Asbestos-cement board . 1/8 m. Boards, Panels, Gypsum or plaster board . 3/8 bi. Sheathing, Etc . Gypsum or plaster board . 1/2 in. Plywood. . . Plywood. . . Plywood. . . . 3/8 in. Plywood. . . . 1/2 in. Plywood. . . Plywood. . . . 3/4 bi. Shealhhig (impreg. or coated).............. 1.1720 _ 0.2344 _ _ _ _ 0.1113 0.4776 0.4688 0.4278 0.3868 0.3164 1.7580 9.6690 0.9083 0.6593 _ 0.9376 0.6212 0.4688 0.3897 0.3135 - - 0.853 _ _ 4.266 _ 8.976 2.082 2.116 2.321 2.594 3.140 0.580 1 126 1.092 1.536 1.058 1.604 2.150 2.662 3.208 - 4.00 - 0.80 - - - - 0.38 1.63 1.60 1.46 1.32 1.08 6.00 - 33.00 3.10 2.25 - 3.20 2.12 1.60 1.33 1.07 - _ " 0.25 - 1.25 - - 2.63 0.61 0.62 0.68 0.76 0.92 0.17 - 0.33 0.32 0.45 - 0.31 0.47 0.63 0.78 0.94 - SLSO 63099 7-7 Table 7-2. Thermal Properties of Building Materials* (Coat) For Heat Loss in Watts Material Description (k) (C) (1/k) (1/C) Sheathing (impreg. or coated)................................... 1/2 in. Sheathing (impreg. or coated)............................... 25/32 in. Wood fiber board, laminated .... or homogeneous............................... Wood fiber--hardboard type .... Wood fiber--hardboard type 1/4 in. BUILDING PAPER Vapor--permeable felt..................... Vapor--seal, 2 layers of mopped 15 lb felt.......................................... Vapor--seal, plastic film.............. - - 0.1612 0.1231 0.4102 - - FLOORING MATERIALS Carpet and fibrous pad .................. Carpet and rubber pad..................... Cork tile........................................ 1/8in. Terrazzo ...................................... 1 in. Tile--asphalt, linoleum, vinyl, rubber................................... Wood subfloor................. 25/32 in. Wood, hardwood finish . . . 3/4 in. - - - INSULATING Cotton fiber............................. MATERIALS Mineral wool, fibrous form, Blanket and Batt processed from rock, slag, or glass............................... Wood fiber............................ Board and Slabs Cellular glass..................... Corkboard 9(.S0 6Z099 0.0762 0.0791 0.0733 0.1172 0.1143 0.1084 0.1026 0.0967 0.0938 0.0820 0.0791 0.0762 0.0733 0.0703 0.0674 0.0908 0.0879 0.0850 0.0820 0.2227 0.1436 - 1.6408 4.8931 2.4466 " 0.1406 0.2373 1.0548 3.6625 5.8600 0.2989 0.4307 - - - 6.212 8.123 2.457 - _ _ - _ - - 13.140 12.628 - 13.652 - 8.533 - 8.737 - 9.215 - 9.761 - 10.239 - 10.649 - 12.184 - 12.628 - 13.106 - 13.652 - 14.232 - 14.847 - 10.990 - 11.365 - 11.775 - 12.184 4.505 7.031 - 0.614 0.205 0.410 - 7.099 4.198 0.956 0.273 0.171 3.345 2.321 - - __ _ _ _ __ _ .. _ _ - For Heat Loss in BTUH (k) (C) (1/k) - _ 0.55 0.42 1.40 - - - - - - 0.26 0.76 0.49 _ _ _ 5.60 16.70 8.35 " 0.48 0.81 3.60 12.50 20.00 1.02 1.47 - - 1.82 2.38 0.72 - _ - - - - 3.85 0.27 0.25 0.40 0.39 0.37 0.35 0.33 0.32 0.28 0.27 0.26 0.25 0.24 0.23 0.31 0.30 0.29 0.28 3.70 - 4.00 - 2.50 - 2.56 - 2.70 - 2.86 - 3.00 - 3.12 - 3.57 - 3.70 - 3.84 - 4.00 - 4.17 - 4.35 - 3.22 - 3.33 - 3.45 - 3.57 (1/C) 1.32 2.06 _ _ _ 0.18 0.06 0.12 Negl. 2.08 1.23 0.28 0.08 0.05 0.98 0.68 - - _ _ _ _ _ _ _ _ _ _ _ - Table 7-2. Thermal Properties o Building Materials* (Cont) Material Loose Fill ft7f)CTrr For Heat Loss in Watts Description 00 (C) d/k) (1/C) Glass fiber............................................. Expanded rubber................................... Hog hair (with asphalt binder).................................................... Expanded polystyrene........................ Mbieral wool with resin binder.................................................... Mineral wool with asphalt binder.................................................... Wood or cane fiberboard Acoustical tile................. 1/2 in. Acoustical tile................. 3/4 in. Interior finish (plank, tile).............. Interior finish (plank, tile) 1/2 in. Insulating Roof Deck Approximately..............1-1/2 in. Approximately.....................2 in. Approximately.....................3 in. Wood shredded (cemented in preformed slabs)............................ Macerated paper or pulp products . . Mineral wool (glass, slag, or rock) . .............................. * . . . . 0.0791 0.0762 0.0733 0.0615 0.0498 0.0615 0.0967 0.0850 0.0820 0.0733 0.0674 0.0586 0.0850 0.0820 0.0791 0.0733 0.0703 0.0674 0.0908 0.0879 0.0850 0.0791 0.1026 - - 0.1612 0.0820 0.0879 0.0879 0.0791 0.0733 0.0674 0.0586 _ 12.628 - 13.106 - 13.652 - 16.246 - 20.068 - 1 15.529 ~ 10.239 - 11.775 - 12.184 - 13.652 - 14.847 - 17.065 - 11.775 - 12.184 - 12.628 - 13.652 - 14.232 - 14.847 - 10.990 - 11.365 - 11.775 - 12.628 0.2461 0.1641 - 0.2051 - 9.761 - 0.0703 0.0527 0.0352 - - 6.212 - 12.184 - 11.365 - 11.365 - 12.628 - 13.652 - 14.847 - 17.065 - - - - - - - 4.061 6.075 4.881 14.232 18.976 28.430 _ _ - _ - For Heat Loss in BTUH (k) (C) (1/k) (1/C) 0.27 0.26 0.25 0.21 0.17 0.21 _ 3.70 - 3.84 - 4.00 - 4.76 - 5.88 - 4.55 - - 0.33 0.29 0.28 0.25 0.23 0.20 0.29 0.28 0.27 0.25 0.24 0.23 0.31 0.30 0.29 0.27 0.35 - - - - - - - 0.84 0.56 - 0.70 3.00 3.45 3.57 4.00 4.35 5.00 3.45 3.57 3.70 4.00 4.17 4.35 3.22 3.33 3.45 3.70 - - 2.86 - - - - - 1.19 1.78 - 1.43 - 0.24 - 4.17 - 0.18 - 5.56 - 0.12 - 8.33 0.55 0.28 0.30 0.30 0.27 0.25 0.23 0.20 - 1.82 - 3.57 - 3.33 - 3.33 - 3.70 - 4.00 - 4.35 - 5.00 - - - - - - - Table 7-2. Thermal Properties of Building Materials* (Cont) 7-9 Material Roof Insulation MASONRY MATERIALS Concretes 8Z.50 63099 Description Sawdust or shavings Silica aerogel. . . . Vermiculite (expanded) Wood fiber: redwood, hemlock, or fir.......................................... Wood fiber: redwood bark . . . Preformed, for use above deck Approximately . . . ... 1/2 in Approximately . . .............. 1 in Approximately . . . . .1-1/2 in Approximately . . .............. 2 in Approximately . . . . . 2-1/2 in Approximately . . .............. 3 in Cellular glass Cement mortar....................................... Gypsum-fiber concrete 87-1/2% gypsum, 12-1/2% wood chips . . . Lightweight aggregates including . . expanded shale, clay or slate; . . . expanded slags; cinders;'.................. pumice; perlite; vermiculite; . . . . also cellular concretes..................... For Heat Loss in Watts 00 0.0527 0.1319 0.0498 0.0469 0.0440 0.0440 0.0410 0.0381 0.1406 0.1406 0.1348 0.1289 0.1231 0.1172 0.1113 0.0879 0.0908 0.0820 0.0762 0.0733 0.0674 0.0352 0.0586 (C) - _ " (1/k) 18.976 7.577 20.068 21.331 23.072 23.072 24.369 26.246 7.099 7.099 7.440 7.748 8.123 8.533 8.976 11.365 10.990 12.184 13.106 13.652 14.847 16.246 17.065 (1/C) _ _ .. _ _ _ _ _ _ _ - . _ _' - _ _ - * - 0.1143 1.4650 0.4864 1.5236 1.0548 0.7325 0.4981 0.3370 0.2637 0.2051 0.2110 0.1055 0.0703 0.0557 0.0440 0.0352 - - _ - - - - - . 8.737 0.683 2.048 0.648 0.956 1.365 2.014 2.935 3.788 4.881 4.744 9.488 14.232 17.952 22.765 28.430 - - _ - - - - - - For Heat Loss in BTUH 00 0.18 0.45 0.17 0.16 0.15 0.15 0.14 0.13 0.48 0.48 0.46 0.44 0.42 0.40 0.38 0.30 0.31 0.28 0.26 0.25 0.23 0.12 0.20 (C) (1/k) _ 5.56 2.22 5.88 _ 6.25 _ 6.76 _ 6.76 7.14 _ 7.69 2.08 2.08 _ 2.18 2.27 2.38 2.50 - 2.63 _ 3.33 3.22 - 3.57 3.84 - 4.00 _ 4.35 - 4.76 - 5.00 (1/C) _ _ _ _ _ _ _ _ .. - _ _ _ _ _ - 0.39 5.00 1.66 5.20 3.60 2.50 1.70 1.15 0.90 0.70 0.72 0.36 0.24 0.19 0.15 0.12 - - _ _ - * - 2.56 0.20 0.60 0.19 0.28 0.40 0.59 0.86 1.11 1.43 1.39 2.78 4.17 5.26 6.67 8.33 - - - - . - Table 7-2. Thermal Properties of Building Materials* (Cont) For Heat Loss in Watts For Heat Loss in BTUH Material Description Sand and gravel or stone aggregate (oven dried)...................................... Sand and gravel or stone aggregate (not dried).......................................... Stucco.................................................... 00 2.6370 3.5160 1.4650 (C) _ - (1 A) 0.375 0.273 0.683 (1/C) _ - 00 9.00 12.00 5.00 (C) (i A) (1/C) - 0.11 _ 0.08 - 0.20 - - 7-10 MASONRY UNITS 6Z.S0 63039 Brick, common................................... Brick, face.......................................... Clay tile, hollow: 1 cell deep...............................3 in. 1 cell deep...............................4 in. 2 cells deep...............................6 in. 2 cells deep...............................8 in. 2 cells deep............................ lOin. 3 cells deep............................12 in. Concrete blocks, three oval core: Sand and gravelaggregate . 4 in. .... 8 in. ... .12 in. Cinder aggregate......................3 in. .................... 4 in. .................... 8 in. .................. 12' in. Lightweight aggregate .... 3 in. (expanded shale, clay, . . . 4 in. slate or slag; pumice). ... 8 in. . . . .12 in. Concrete blocks, rectangular core: Sand and gravel aggregate 2 core, 8 in. 36 lb..................... Same with filled cores.............. Lightweight aggregate (expanded shale, clay, slate or slag, pumice): 3 core, 6 in., 19 lb..................... Same with filled cores.............. 2 core, 8 in., 24 lb..................... Same with filled cores.............. 3 core, 12 in., 38 lb................. Same with filled cores.............. Stone, lime or sand........................ Gypsum partition tile: ' 3 x 12 x 30 in. solid..................... 3 x 12 x 30 in. 4-cell..................... . 1.4650 2.6370 _ - _ - - 3.6625 _ - - 0.3663 0.2637 0.1934 0.1582 0.1319 0.1172 0.4102 0.2637 0.2285 0.3399 0.2637 0.1699 0.1553 0.2315 0.1963 0.1465 0.1289 0.2813 0.1524 0.1787 0.0967 0.1348 0.0586 0.1172 0.0498 0.2315 0.2168 0.683 0.375 _ - - ~ - 0.273 _ - _ - 2.730 3.788 5.188 6.314 7.577 8.533 2.423 3.788 4.369 2.935 3.788 5.870 6.451 4.335 5.120 6.826 7.748 3.550 6.587 5.631 10.205 7.440 17.167 8.464 19.864 - 4.300 4.608 5.00 9.00 _ _ - _ _ . - * _ - 1.25 0.90 0.66 0.54 0.45 0.40 1.40 0.90 0.78 1.16 0.90 0.58 0.53 0.79 0.67 0.50 0.44 0.96 0.52 0.20 0.11 _ - - - - . ' _ . _ - 12.50 . - 0.61 0.33 0.46 0.20 0.40 0.17 - 0.79 0.74 - 0.08 _ - - - 0.80 1.11 1.52 1.85 2.22 2.50 0.71 1.11 1.28 0.86 1.11 1.72 1.89 1.27 1.50 2.00 2.27 1.04 1.93 1.65 2.99 2.18 5.03 2.48 5.82 1.26 1.35 Table 7-2. Thermal Properties of Building Materials* (Cont) Material METALS PLASTERING MATERIALS ROOFING Description 4 x 12 x 30 in. 3-cell . . . Aluminum ............................ Brass (70-30)........................ Cast-Iron................................ Copper ................................... Glass ....................................... Lead . . .'............................ Nickel. . . ............................ Soil.......................................... Steel, mild............................ Water...................................... Cement plaster, sand aggregate . . Sand aggregate................. 1/2 in. Sand aggregate................. 3/4 in. Gypsum plaster: Lightweight aggregate. . . 1/2 in. Lightweight aggregate. . . 5/8 in. Lightweight agg. on metal lath....................................... 3/4 in. Perlite aggregate.............. Sand aggregate................. Sand aggregate................. 1/2 in. Sand aggregate................. 5/8 in. Sand aggregate on metal lath...................................... 3/4 in. Sand aggregate on wood lath...................................... Vermiculate aggregate . . Asbestos-cement shingles . Asphalt roll roofing . . . . Asphalt shingles................. Built-up roofing................. 3/8 in. Slate ...................................... 1/2 in. Wood shingles..................... For Heat Loss in Watts (k) (C) - 0.1758 414.8880 210.9600 98.4480 773.5200 1.0557-2.1114 70.3200 119.5440 0.7038-0.3519 91.4160 1.1954 1.4650 - _ 1" - - 2.9300 1.9514 _ 0-9142 - 0-7823 (1/k) - 0.002 0.003 0.010 0.001 0.014 0.007 - 0.010 0.853 0.683 - . - _ 0.4395 1.6408 - .. 0.6241 - 3.2523 2.6663 2.2561 2.287 0.614 - - 0.4981 _ - - - - 0.7325 1.3947 1.9045 0.6651 0.8790 5.8600 0.3106 2.014 _ - - (1/C) 5.700 0.341 0.512 1.092 1.331 1.604 - 0-307 0.375 0.341 1.365 - 0.717 0.512 1.502 1.126 0.171 3.208 For Heat Loss in BTUH (k) .- . 1416.00 . 720.00 . 336.00 . 2640.00 3.60-7.20 . 240.00 . 408.00 2.40-12.00 . 312.00 . 4.08 . 5.00 - _ - _ . 1.50 . 5.60 - . . 1.70 (C) 0.60 . _ - _ - - 10.00 6.66 3.12 2.67 2.13 - 11.10 9.10 7.70 2.50 " (1/k) - 0.0007 0.0010 0.0030 0.0004 0.0040 0.0020 0.0030 0.2500 0.2000 - _ - 0.6700 0.1800 - - . . 0.5900 (1/C) 1.67 - - - - 0.10 0.15 0.32 0.39 0.47 - 0.09 0.11 0.10 0.40 - ..- 4.76 6.50 2.27 - - - 3.00 - - 20.00 - .- 1.06 - 0.21 0.15 0.44 0.33 0.05 0.94 7-11 SIDING Shingles: MATERIALS Asbestos-cement.............. (On Flat Surface) Wood, 16 in., 7-1/2 in. exposure ........................ Wood, double, 16-in., 0850 6Z099 12-in. exposure.............. 1.3947 0.717 4.76 0.21 _ 0.3370 2.969 1.15 0.87 - 0.2461 - 4.061 . - 0.84 - 1.19 Material WOODS Table 7-2. Thermal Properties of Building Materials* (Cont) For Heat Loss in Watts For Heat Loss in BTUH Description (k) <C) (1/k) (1/C) (k) (C) (1/k) (1/C) Wood, plus insul. backer board.............. ... 5/16 in. Siding: Asbestos-cement, 1/4 in., lapped...................................... Asphalt roll siding............................ Asphalt insulating siding (1/2 in. bd.)....................................... Wood, drop, 1 x 8 In.......................... Wood, bevel, 1/2 x 8 in., lapped................................................. Wood bevel, 3/4 x 10 in., lapped................................................. Wood, plywood, 3/8 in., lapped................................................. Structural glass................................... Maple, oak, and similar hardwoods .......................................... Fir, pine, and similar softwoods.............................................. Fir, pine, and similar softwoods......................... 25/32 ini .........................1-5/8 in. .........................2-5/8 in. ........................ 3-5/8 in. - - - - . - 0.3223 0.2344 - - 0.2080 1.3947 1.9045 0.2022 0.3721 0.3604 0.2784 0.4659 2.9300 - 0.2989 0.1436 0.0879 0.0645 _ __ 3.106 4.266 _ _ - - 4.778 0.717 0.512 4.983 2.696 2.765 3.584 2.014 0.341 _ _ 3.345 6.928 11.195 15.529 - - 1.10 0.80 - 0.71 4.76 6.50 0.69 1.27 1.23 0.95 1.59 10.00 - - 1.02 0.49 0.30 0.22 - - - - - 0.91 1.25 " 1.40 0.21 0.15 1.46 0.79 0.81 1.05 0.59 0.10 - - 0.98 2.03 3.28 4.55 Extracted from 1963 ASHRAE Guide and Data book. NOTES: L Data in terms of Watt In. Hr. Sq. Ft. UF 2_ Data in terms of Hr. Sq. Ft. Watt F 3_ Data in terms of Btu In. Hr. Sq. Ft. F 4^ Data in terms of Hr. Sq. Ft. F Btu T8S0 6Z0SS ACTIVE WIDTH (feet) 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 Table 7-3. Electrical Characteristics of THERMALUX Heating Panel LENGTH (feet) 2 3 4 5 6 7 8 9 10* 11 12* 4 5 6 7 8 9 10* 11 12* R (ohms) 240.00 160.00 120.00 96.00 80.00 68.50 60.00 53.30 48.00 43.60 40.00 60.00 48.00 40.00 34.30 30.00 26.65 24.00 21.80 20.00 I (amperes) 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 P (watts) 60 90 120 150 180 210 240 270 300 330 360 240 300 360 420 480 540 600 660 720 Figure 7-3. Heat Output of Panels Versus Voltage Input 7-13 Table 7-4. Heat Loss Calculation Formulas Kwatts = - 293 KBtuh KBtuh = 3` 413 Cwatts Cwa,t,ts = 0. 293 CB_.tuh. CBtuh " 3- 413 Cwatts Rohms = 1/U Rwatts = 1/W R = X/k R = 1/C RBTMtu.h. = 0. 293 Rwa,,tts Rwa,,tts = 3. 413 RBnt.uh. RT = R1 + R2 + R3 + ` ' RN W = 1/Rt (Rt in watts) " U = 3.413 W W = 0. 293 U U = 1/Rt (Rt in Btuh) TD = Tinside - Toutside HL = W x A x TD HLtrans = w x A x TD (HL in watts) HLinfil = ' 0053 x v x CH x TD (HL in watts) HLtrans = u x A x TD (HL in Btu) HLinfil = - 018 x v x CH x TD (HL in Btu) HL.tot. a,l = HLt,rans + HL.m.f.i.l HLBtu = 3. 413 HLwatts HLwa,t,ts = 0. 293 HLBDt.u DD = 65 T1 high + T low Table 7-5. Electrical Formulas E = IR E = PI I = E/R I = P/E R = E/I P = El P = I2R P = e2/r THERMALUX Rinsta^ = 960 ohms/sq. ft. of heating panel THERMALUX I. . ,, = 0.125 amps x sq.ft, of heating panel THERMALUX Iinsta^ = Area of Heating Panel/8 THERMALUX pinstay = 15 watts x sq. ft. of heating panel R in parallel 1/RT = 1/R1 + 1/R2 + l/Rj + . . 1/RN R in series RT = R^ + R2 + Rg + . . RN KWH = (FHA frmula) KWH = HL Xj^-X-- (NEMA formula) HEATING COST = KWH x Rate Table 7-6. Room Air Changes Per Hour Type of Room 1 side exposed 2 sides exposed 3 sides exposed 4 sides exposed Entrance Hall Air Changes Per Hour Without Storm Sash on Windows and Doors With Storm Sash on Windows and Doors 1 1-1/2 2 2 2 to 3 1/2 3/4 1 1 1 to 1-1/2 BB029 0583 7-14 Table 7-7. W of Horizontal Glass Sheets (watts per square foot per F) Air Space One Sheet Two Sheets None 1/4" 1/2" or more Outdoor exposure Indoor exposure 0. 41 0. 28 0. 20 0. 17 0. 19 0. 16 Table 7-8. W of Vertical Glass Sheets (watts per square foot per F) Air Space One Sheet Two Sheets None 1/4" 1/2" or more Outdoor exposure Indoor exposure 0. 33 0. 22 0.18 0. 15 0. 16 0.13 Table 7-9. All Weather Comfort Standards Building Section U RBtu W ^Watts Ceilings* Walls Floors over vented crawl spaces 0.05 0.07 0. 07 20. 0 14.3 14. 3 0.0147 0. 0223 0.0223 68.0 45. 6 45. 6 Table 7-10. W of Wall Sections of Hollow Glass Block (watts per square foot per F) Size of Block Outside Wall Section 5-3/4"x5-3/4"x3-7/8" thk 7-3/4" x 7-3/4" x 3-7/8" thk ll-3/4"x ll-3/4"x3-7/8" thk 0.18 0.17 0. 15 Inside Wall Section 0. 14 0.13 0. 12 Table 7-11. Floor Slab Heat Loss (watts per lineal ft. of exposed slab edge) Outside Design Temperature 24" Insulation (Horizontal + Vertical) 2" thick 1" thick No Insulation -20 to -30 15 17 22 -10 to -20 13 15 19 0 to -10 11 13 18 Table 7-12. Heating Branch Circuit Capacities Branch Circuit Conductor Size Max. Load-Amps (20% Derated) Maximum Installed Area of Heating Panel 2-Wire 3-Wire Circuit Circuit #14 #12 #10 12 16 24 96 192 128 256 192 384 Table 7-13. W of Solid Wood Doors (watts per square foot per OF) Nominal Thickness Actual Exposed Thickness Door With Glass Storm Door 1" 1-1/4" 1-1/2" 1-3/4" 2" 2-1/2" 3" 25/32" 1-1/16" 1-5/16" 1-3/8" 1-5/8" 2-1/8" 2-5/8" 0. 19 0. 16 0. 14 0. 14 0. 13 0. 11 0. 09 0. 11 0.10 0. 09 0. 09 0.08 0. 08 0.07 Table 7-14. Correction Factors for Window Framing Type of Window Sash % Glass None Wood Wood Steel Aluminum 100 80 60 80 80 Single Glass 1.0 0.9 0.8 1. 0 1.1 Factor Double Glass Window with Storm Sash 1.00 0.95 0. 85 1. 20 1.30 -- 0.9 0.8 1. 0 1.1 7-15 Mocdoo oon 00