Advice on joining UFH wires

[MartK]

Hi all,

I'm attempting a repair on a comfort zone underfloor heating mat.

The customer lifted a floor tile and in doing so cut through the cable. Fortunately there is enough slack to complete a join but I have one shot left at this having already tried with butt connectors and heat shrink...

Grom outsude in, the cable consists of a white pvc protection, aluminium foil jacket, one copper conductor and two earth conductors each within a clear sleeving.

The copper heating conductor is thick enough to get a butt crimp on but the earth conductors are almost as thin as hair and on my first attempt have broken at the slightest of pressure of my crimper. I'm not keen to double the wires over to increase thr csa as I'm sure they'd just break.

Can anybody give me some advice on the best way to join wires as thin as hair? This is my last chance before I have to take another tile up

Many thanks
Martin

 

[Silly Sausage]

Hmmmm, not sure.
Maybe time to get the soldering iron out?

 

[Midwest]

Even maybe ask the manufacturer if it’s a goer?

 

[Gazthesparky]

I’m not every sure how you would go about fixing it. I would speak to the manufacturers they might even offer a repair service. Soldering the joint probably won’t work as the solder will melt as the wire heats up.

But crimps won’t be great either as it will add resistance to the mat and alter the heating power

 

[Andy5678]

Can you post a photo of the damage?

 

[westward10]

If you know the manufacturer most supply repair kits.

 

[buzzlightyear]

The copper heating conductor is thick enough to get a butt crimp on but the earth conductors are almost as thin as hair and on my first attempt have broken at the slightest of pressure of my crimper. I'm not keen to double the wires over to increase thr csa as I'm sure they'd just break.

Can anybody give me some advice on the best way to join wires as thin as hair?

I would agree with arch enemy ..solder it .

 

[JC Heat]

I know it's very difficult to fix this specific wire. My advice is to get a magnifier, if neccessary, remove another tile, carefully. You need to have steady hands and lots of light. Good luck. Or let us know if you were successful.

 

[telectrix]

I’m not every sure how you would go about fixing it. I would speak to the manufacturers they might even offer a repair service. Soldering the joint probably won’t work as the solder will melt as the wire heats up.

But crimps won’t be great either as it will add resistance to the mat and alter the heating power

the solder will not melt. the cables will never get anywhere near 300 degrees. and that just the element part. the cpc will be even cooler.