Pentair Raychem IceStop User manual

IceStop System
INSTALLATION AND OPERATION MANUAL FOR
ROOF AND GUTTER DE-ICING SYSTEMS
THERMAL MANAGEMENT WWW.PENTAIRTHERMAL.COM

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Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD.
IceStop roof and gutter de-icing systems must be
installed correctly to ensure proper operation and to
prevent shock and fire. Read these important warnings
and carefully follow all the installation instructions.
•To minimize the risk of fire from sustained electrical
arcing if the heating cable is damaged or improperly
installed and to comply with Thermal Management
requirements, agency certifications, and national
electrical codes, ground-fault equipment protection
must be used on each heating cable branch circuit.
Arcing may not be stopped by conventional circuit
breakers.
•Approvals and performance are based on the use of
Raychem parts only. Do not substitute parts or use
vinyl electrical tape.
•Bus wires will short if they contact each other. Keep
bus wires separated.
•Connection kits and cable ends must be kept dry
before and during installation.
•The black heating cable core and fibers are conduc-
tive and can short. They must be properly insulated
and kept dry.
•Damaged bus wires can overheat or short. Do not
break bus wire strands when scoring the jacket or
core.
•Damaged heating cable or connection kits can cause
electrical shock, arcing or fire. Do not attempt to
repair or energize damaged cable. Remove damaged
sections at once and replace them with a new length
using the appropriate Raychem splice kit. Replace
damaged connection kits.

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Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
Table of Contents
1 General Information 1
1.1 UseoftheManual 1
1.2 IceStopApplications 1
1.3 SafetyGuidelines 2
1.4 TypicalRoofandGutterSystem 3
1.5 Approvals 6
1.6 Warranty 6
2 Pre-Installation Checks 7
2.1 CheckMaterials 7
2.2 ConnectionKitsandAccessories 8
2.3 ReviewtheDesign 12
3 Heating Cable Installation 13
3.1 HeatingCableHandling 13
3.2 ProtectingtheHeatingCable 14
3.3 VisualInspection 14
3.4 HeatingCableLayout 15
4 Attachment Methods 29
4.1 Overview 29
4.2 RoofAttachmentMethods 30
4.3 AttachmentMethodsforOtherAreas 35
5 Control, Monitoring and Power Distribution 39
5.1 ControlSystems 39
5.2 PowerDistribution 44
6 Commissioning and Preventive Maintenance 48
6.1 SystemStart-upandOperation 48
6.2 InsulationResistance(Megohmmeter)Test 48
6.3 ContinuityTest 51
7 Test Procedures 52
7.1 Tests 52
7.2 InsulationResistanceTest–Test1 52
7.3 InsulationResistance(Megohmmeter)Test 53
7.4 FaultLocationTests 56

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8 Troubleshooting Guide 60
9 Installation and Inspection Records 66

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1
General Information
1.1 Use of the Manual
ThismanualcoverstheinstallationofRaychem
IceStoproofandgutterde-icingsystem.Themanual
coversgeneralheatingcableinstallationprocedures
andspecificinstallationdetailsandshowsavailable
connectionkits.Themanualalsodiscussescontrols,
testing,andperiodicmaintenance.
Thismanualassumesthattheproperroofandgutter
de-icingdesignhasbeencompletedaccordingtothe
RoofandGutterDe-Icing:IceStopSystemDesign
Guide(H56070).
OnlytheapplicationsdescribedinSection1.2are
approvedbyThermalManagementforIceStop
systemswhenusedwithapprovedRaychem
connectionkits.Theinstructionsinthismanual
andtheinstallationinstructionsincludedwiththe
connectionkitsmustbefollowedfortheThermal
Managementwarrantytoapply.Contactyour
ThermalManagementrepresentativeforother
applicationsandproducts.
1.2 IceStop Applications
RaychemIceStopisaroofandgutterde-icingsystem
thatprovidesdrainpathsforthefollowing
applications:
•Roofsmadefromstandardroofingmaterials,
includingshake,shingle,rubber,tar,wood,metal,
andplastic.
•Guttersmadefromstandardmaterials,including
metal,plastic,andwood.
•Downspoutsmadefromstandardmaterials,
includingmetalandplastic.
Theguidedoesnotprovideinformationforusingan
IceStopsystemforthefollowingapplications:
•Preventingsnowmovementonroofs—IceStopwill
notkeepsnoworicefromfallingofftheroof.
IceStopisdesignedtoremovemeltwater,not
accumulatedsnow.Snowfencesorsnowguards
shouldbeusedtoeliminatesnowmovement.

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1
General Information
Forthenamesofmanufacturersofsnow
guardsorsnowfences,contactyourThermal
Managementrepresentative,orcontactusdirectly
at(800)545-6258.
•Meltingsnowonaroofand/orreductionofsnow
load—IceStopisdesignedtoremovemeltwater,not
accumulatedsnow.
Ifyourapplicationconditionsaredifferent,orifyou
haveanyquestions,contact:
Thermal Management
7433HarwinDrive
Houston,TX77036
USA
Tel: +1.800.545.6258
Tel: +1.650.216.1526
Fax: +1.800.527.5703
Fax: +1.650.474.7711
[e-mail]
www.pentairthermal.com
1.3 Safety Guidelines
Thesafetyandreliabilityofanyheat-tracingsystem
dependsonthequalityoftheproductsselected
andthemannerinwhichtheyareinstalledand
maintained.Incorrectdesign,handling,installation,
ormaintenanceofanyofthesystemconnectionkits
coulddamagethede-icingsystemortheroofand
mayresultininadequatede-icing,electricshock,or
fire.Tominimizetheserisksandtoensurethatthe
systemperformsreliably,readandcarefullyfollow
theinformation,warnings,andinstructionsinthis
guide.
•Importantinstructionsaremarked Important
•Warningsaremarked WARNING

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1
General Information
1.4 Typical Roof and Gutter System
Icedamscancausewateringressintobuildingsand
generatedangerousicicles.AnIceStopsystemcan
helppreventicedamsandiciclesbymaintaining
acontinuouspathformeltwatertodrainfromthe
roof.Aslongasaheatedpathfromtherooftoa
safedischargeareaismaintained,icedamswillnot
form.TheIceStopsystemcanbeusedonroofsand
valleysandindownspoutsandguttersmadefromall
typesofstandardroofingmaterials,includingmetal,
plastic,wood,shake/shingle,rubber,andtar.
TheIceStopsystemisintendedtoprovidedrain
paths.AtypicalsystemisshowninFigure1.

4Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
1
General Information
Power Connection Kits Splice Kits
Attachment Kits Tee Kits
Gutter Sensor
Downspout Hanger Kit End Seal Kit
Heating Cable
Lighted End
Power Distribution Panel
APS-4
SUPPLY
SNOW
HEATER
GROUND FAULT
GROUND FAULT
HEATER CYCLE
RESET
TEST
HOLD ON TIME (HRS)
Snow/Ice Melting Controller
SUPPLY: 277 VAC, 50/60HZZ, 35VA
HEATER:377 VAC, 40 AMP. MAX RESIS
USEONLY COPPER CONDUCTORS HAVING
SUFFICIENTAMPACITY.
SEEINSTALLATION INSTRUCTIONS
WARNING
DANGEROF ELECTRICAL SHOCK OR ELCTROCUTION
Lethalvoltages are present beneath this cover. Servicee by
qualifiedpersonnel only. More than one disconnect may be
requiredto de-energize this control for servicing.
GROUND FAULT
GROUND FAULT
HEATER CYCLE
HOLD ON TIME (HRS)
SNOW
HEATER
GROUND FAULT
GROUND FAULT
HEATER CYCLE
RESET
TEST
HOLD ON TIME (HRS)
SUPPLY: 277 VAC, 50/60HZZ, 35VA
HEATER:377 VAC, 40 AMP. MAX RESIS
USEONLY COPPER CONDUCTORS HAVING
SUFFICIENTAMPACITY.
SEEINSTALLATION INSTRUCTIONS
WARNING
DANGEROF ELECTRICAL SHOCK OR ELCTROCUTION
Lethalvoltages are present beneath this cover. Servicee by
qualifiedpersonnel only. More than one disconnect may be
requiredto de-energize this control for servicing.
APS-4
SUPPLY
Snow/Ice Melting Controller
Snow Controller
Figure 1: IceStop Roof and Gutter De-Icing System

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1
General Information
Power Connection Kits Splice Kits
Attachment Kits Tee Kits
Gutter Sensor
Downspout Hanger Kit End Seal Kit
Heating Cable
Lighted End
Power Distribution Panel
APS-4
SUPPLY
SNOW
HEATER
GROUND FAULT
GROUND FAULT
HEATER CYCLE
RESET
TEST
HOLD ON TIME (HRS)
Snow/Ice Melting Controller
SUPPLY: 277 VAC, 50/60HZZ, 35VA
HEATER:377 VAC, 40 AMP. MAX RESIS
USEONLY COPPER CONDUCTORS HAVING
SUFFICIENTAMPACITY.
SEEINSTALLATION INSTRUCTIONS
WARNING
DANGEROF ELECTRICAL SHOCK OR ELCTROCUTION
Lethalvoltages are present beneath this cover. Servicee by
qualifiedpersonnel only. More than one disconnect may be
requiredto de-energize this control for servicing.
Snow Controller

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1
General Information
1.5 Approvals
TheIceStoproofandgutterde-icingsystemisUL
Listed,CSACertified,andFMApprovedforusein
nonhazardousareas.GM-1XTandGM-2XTarealso
FMApprovedforuseinClassI,Division2hazardous
locations.
1.6 Warranty
ThermalManagement'limitedstandardwarranty
appliestoallproducts.Youcanaccessthecomplete
warrantyatwww.pentairthermal.com.Toqualifyfor
anextended10-yearwarranty,registeronlinewithin
30daysofinstallationatwww.pentairthermal.com.

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Pre-Installation Checks
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2.1 Check Materials
Ifphysicaldamageisfound,theentiredamagedsec-
tionmustberemovedandanewsectionofheating
cablesplicedin,usingonlyapprovedRaychemsplice
kits.Donotattempttorepairthedamagedheating
cablesection.Ifthedamagecannotbefound,the
completecircuitshouldberemovedandreplaced
withnewIceStopheatingcable.
WARNING: Shock or Fire Hazard. Damaged
heating cable or connection kits can cause electrical
shock, arcing, and fire. Do no attempt to energize
damaged heating cable or connection kits. Replace
them immediately using a new length of heating cable
and the appropriate IceStop accessories.
Catalog number: GM — 1 or 2 XT X
Product family
Voltage 1 = 120 V
2 = 208-277 V
Jacket type: Fluoropolymer
Polyolefin
or
or
Figure 2: Catalog number

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Pre-Installation Checks
Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
2.2 Connection Kits and Accessories
TABLE 1:
CONNECTION KITS
Catalog number
Description
Heating cable
allowance
1
Power connection
RayClic-PC
Quickconnectpowercon-
nectionkittopower1run
ofheatingcable.Includes1
endseal.
Standard pkg:1
2ft(0.6m)
RayClic-PS
Quickconnectpowercon-
nectionkittopower2runs
ofheatingcable.Includes2
endseals.
Standard pkg:1
2ft(0.6m)
RayClic-PT
Quickconnectpowercon-
nectionkittopower3runs
ofheatingcable.Includes3
endseals.
Standard pkg:1
3ft(1m)
RayClic-LE
Alternatelightedendseal
Standard pkg:1
2ft(0.6m)
R
RayClic-X
Crossconnectiontocon-
nectfourheatingcables
Standard pkg:1
8ft(2.4m)
End seal
RayClic-E
Extraendseal
Standard pkg:1
0.3ft(0.1m)

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Pre-Installation Checks
Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
TABLE 1:
CONNECTION KITS
Catalog number
Description
Heating cable
allowance
1
Junction box
FTC-P
Junctionbox1mounted
HSPpowerconnectionkits.
Includes1endseal.
Standard pkg:1
2ft(0.6m)
Splice connection
RayClic-S
Quickconnectsplicekit
Standard pkg:1
2ft(0.6m)
FTC-HST
Heat-shrinkablesplicekit
Standard pkg:2
2ft(0.6m)
Tee connection
RayClic-T
Quickconnectteekit
Standard pkg:1
2ft(0.6m)
FTC-HST2
Heat-shrinkableteekit
Standard pkg:2
2ft(0.6m)
1 Junctionboxnotincluded.
2 OneRayClic-EendsealisrequiredforeachFTC-HSTusedas
ateekit.

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TABLE 2:
ATTACHMENT ACCESSORIES
Catalog number
Description
No. of packages required
Mounting bracket
RayClic-SB-02
RayClicwall
mounting
bracket
Standard pkg:1
1mountingbracket/
RayClicconnectionkit
(exceptRayClic-E)installed
onawall
GMK-RC
Mechanical
(penetrating)
roofclip
Standard pkg:50
1boxper35'ofroofedge
whenzig-zaglayoutis
used
GM-RAKE
Hangerbracket
Standard pkg: 1
1hangerpercablein
downspoutorasrequired
formechanicalprotection
CT-CABLE-TIE UV-resistant
cabletie
Standard pkg: 100
Variesdependingon
installation

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Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
Adhesives for Metal Roofs
Withtheadhesivesthatareavailabletoday,the
attachmentofclipstometalroofscanbeasreliable
asscrewsornailsintoawoodenroof.Theadhesives
thatperformthebestallowsomeflexibilityinthe
connectionbetweentheclipandtheroofsurface.
Adhesivessuchasepoxies,whichcuretoahard
nonflexibleform,shouldnotbeused.Acid-curing
silicones,whicharenotasstrongandcoulddamage
theroof,alsoshouldnotbeused.
Theadhesiveslistedbelowhavebeenevaluatedby
ThermalManagement.
TABLE 3:
ADHESIVES FOR METAL ROOFS
Adhesive
Description
Times
Dispensing
equipment
Momentive
Performance
Materials,Inc.
RTV167
Neutral-cure
silicone
adhesive
Tooling
20min
Cure
48hr
Caulkinggun
SpeedBonder
H4800
Methacrylate
adhesive
Tooling
45–55min
Cure
24hr
Two-partmixing
dispenser
PlexusMA300 Methacrylate
adhesive
Tooling
15min
Cure
16hr
Two-partmixing
dispenser
PlexusMA310 Methacrylate
adhesive
Tooling
30min
Cure
16hr
Two-partmixing
dispenser
Important: Adhesive is not supplied by Thermal
Management. Contact the manufacturers listed for
information on local distributors. Follow manufac-
turer’s instructions for surface preparation and instal-
lation.

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Raychem-IM-H58067-IceStopRoofGutterDeIcingCOM-EN 18/01
Toolingtimeisthetimebetweenwhentheadhesive
ismixedandbecomesunusableforinstallingmore
clips.Curetimeisthetimeneededtowaitbeforethe
heatingcablecanbeinstalled.
Momentive Performance Materials, Inc. RTV 167
Silicone Adhesiveisaneutral-curesiliconeadhesive.
Contact:(800)332-3390.
SpeedBonder H3300 and H4800aregeneralpurpose,
two-component,room-temperaturecuring,1:1mix
ratio,methacrylateadhesivesystems.Contact:(800)
767-8786.
Plexus MA310 and MA300aretwopartmethacry-
lateadhesivesdesignedforstructuralbondingof
thermoplastic,metal,andcompositeassemblies.
Contact:(800)851-6692.
Pleaseconsultwitharoofingcontractorbeforepur-
chasingandinstallingclipswiththeadhesives.Itis
extremelyimportanttofollowtheadhesivemanufac-
turer’sinstructionscarefully,especiallywithregard
tosurfacepreparation.
2.3 Review the Design
Holdaprojectcoordinationmeeting.Reviewthe
designatthismeetingandensurethatthecables
suppliedmeetthedesignrequirements.
Planthelocationofalljunctionboxesandsupply
points.ReviewtheinstallationstepsinSection3for
theparticularapplicationasseveraltradesmaybe
involvedinthesysteminstallation.ReviewSection
4onattachmentmethods.Duringthemeeting,dis-
cusstheroleofeachtradeandthecontractor.

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3.1 Heating Cable Handling
Paying Out the Cable
Mountthereelonaholderandplaceitneareither
endofthepiperuntobetraced.Useareelholder
thatpaysoutsmoothlywithlittletension.Avoidjerk-
ingthecablewhilepulling.
Whenpayingouttheheatingcable,AVOID:
• Sharpedges
• Excessivepullingforceorjerking
• Kinkingorcrushing
• Walkingonorrunningovertheheatingcablewith
equipment
Connection Kits and Accessories Installation
Startbyinstallingconnectionkitsandaccessories
inlocationsindicatedonprojectdrawingsorasindi-
catedin“HeatingCableLayout”beginningonthe
followingpage.
Onceallclipsanddownspouthangersareinplace,
andadhesivescuredifapplicable,theheatingcable
canbeinstalled.
Startattheendsealandworkback.Besureto
leaveadriploopatconnectionkitssothatwater
willnottrackdowntheheatingcableintothecom-
ponent.Installheatingcableusingthelayoutshown
in"HeatingCableLayout"onpage15foryour
application.
• Besuretheheatingcableprovidesacontinuous
pathforwatertoflowofftheroof.
• Besuretoleavedriploopswhereappropriate.
• Donotexceedmaximumcircuitlengthdeter-
minedduringdesignprocessusingtheRoofand
GutterDe-Icing:IceStopSystemDesignGuide
(H56070).
• Besuretoloopandsecureheatingcableatthe
bottomofdownspoutssothattheheatingcableis
notexposedtomechanicaldamage.
• InstallaUV-resistantcabletiewherevertwoheat-
ingcablesareintendedtostaytogether.

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• Testinstalledheatingcableforinsulation
resistanceandcontinuity(see"Procedure"on
page54).
3.2 Protecting the Heating Cable
Onmanyprojects,thereisadelaybetweeninstalla-
tionoftheheatingcablesandinstallationofheating
systemconnectionkits.Ifthereisanydelayatall,
takethefollowingprecautionstoprotecttheheating
cables.
• Keepcoversonjunctionboxestopreventmois-
turefromenteringthem.
• Mechanicallyprotecttheheatingcablessothat
theycannotbedamagedbybeingwalkedon,run
over,painted,sandblasted,burned,welded,or
cut.
3.3 Visual Inspection
AvisualinspectionoftheIceStopsystemshouldbe
madeafterinstallationiscomplete.Thisinspection
willensure:
• Properinstallationofthesystem
• Nomechanicaldamage(cuts,burns,scrapes,
etc.)tocablesustainedpriortopour
• Properheatingcablespacinganddepth
• Properheatingcablefastening
• Propertreatmentandlocationofexpansionand
controlsjoints
FurthervisualinspectionoftheIceStopsystem
isrecommendedfollowinganyfurtherworkper-
formedonbuildingthatmaycausedamagetothe
system.Furtherworkmayinclude,butisnotlim-
itedto,roofing,gutterordownspoutmaintenance
orrepair,manualsnowremoval,installationof
mechanical,electricalorcommunicationsequip-
mentsuchasantennas,receivers,oraircondition-
ingunits.Also,ifroofsustainsdamageofanykind,
visualandfunctionalinspectionofIceStopsystemis
recommended.

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3.4 Heating Cable Layout
Heatingcablelayoutdependsprimarilyontheroof
typeandrooffeatures.Thefollowingsectionsshow
typicallayoutsonstandardrooftypes:
• "SlopedRoof–Standard"onpage16
• "SlopedRoof–StandingSeam"onpage17
• "FlatRoof"onpage20
• "SlopedRoofwithoutGutters"onpage21
• "RoofValleys"onpage23
• "Roof/WallIntersections"onpage24
• "Gutters"onpage25
• "Downspouts"onpage27
Important: For optimum performance, the heating
cable should be in contact with snow or ice. Installing
the heating cable under the roofing or the roofing
materials will reduce the efficiency of the heating
system. Please contact Thermal Management for
assistance.
Figure3andFigure4followingillustrateseveral
importantterms:
Tracing
width
Tracing
height
Clips
Downspout
hanger
Figure 3: Front view of roof with IceStop system

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12" (30 cm)
Area where ice dams are
most likely to form
Eave overhang
Exterior wall
Heating cable
Gutter
Roof
Heated
area
Figure 4: Side view of roof with IceStop system
Sloped Roof – Standard
Forslopedroofs,icedamsmayformattheroof
edge.Tomaintainacontinuouspathformeltwater
runoff,routetheheatingcableinazig-zagpat-
ternasshowninFigure5andfollowtheappropri-
ateattachmentrecommendationsin“Attachment
Methods‚”page29.Additionalheatingcable
maybeneededforothergutters,downspouts,and
valleys.
2' (60 cm)
Figure 5: Layout in a zig-zag pattern
• Runheatingcableuptheroofuntilitis12inches
(30cm)pasttheexteriorwallintotheheatedarea
(seeFigure4).
• Installtheheatingcableontheroofinazig-zag
patternasshowninFigure5.
• Besurethattheheatingcableextendsalltheway
downtomeetwiththerunofheatingcableinthe