Marley Engineered Products

Introduction

This document provides installation, operation, and maintenance instructions for the Marley MEP-PCA-RG2 Roof and Gutter Components Power Connection Kit.

Tools Required

• Diagonal cutters
• Screw driver
• Needle-nose pliers
• Utility knife
• Heat gun or propane torch

(Junction box not included)

Important Instructions and Warnings

WARNING - The contents of the component kit must be installed correctly to ensure proper operation and to prevent shock or fire. Read these important warnings and carefully follow all the installation instructions.

• To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, use a ground fault protection device. Arcing may not be stopped by conventional circuit breakers.
• Component approvals and performance are based on the use of specified parts only. Do not substitute parts or use vinyl electrical tape.
• The black heating-cable core is conductive and can short. It must be properly insulated and kept dry.
• Damaged bus wires can overheat or short. Do not break bus wire strands when preparing the cable for installation. Bus wires will short if they contact each other. Keep bus wires separated.
• Heat-damaged components can short. Use a heat gun or torch with a soft yellow low-heat flame; not a blue focused flame. Keep the flame moving to avoid overheating, blistering, or charring the heat-shrink tubes. Avoid heating other components. Replace any damaged parts.
• Leave these installation instructions with the user for future reference.

WARNING - Overheating heat-shrink tubes will produce fumes that may cause irritation. Use adequate ventilation and avoid charring or burning.

Power Connection Kit Contents

Installation Instructions

Cable Preparation

Step 1: Cable Structure Overview

Diagram shows a cross-section of the heating cable with layers: Outer jacket, Braid, Inner jacket, Conductive core, and Bus wires (16 AWG).

Step 2: Prepare Cable End

Diagram shows sliding a compression ring, grommet ring, and grommet onto the heating cable.

Step 3: Strip Outer Jacket

Diagram shows stripping the outer jacket approximately 6 1/2 inches from the end. A note indicates "Do not cut through braid or inner jacket."

Step 4: Access Inner Core and Braid

Diagram shows working an opening through the ground braid at the jacket, bending it back, and pulling out the inner core. The braid is twisted into a pigtail.

Step 5: Strip Inner Jacket

Diagram shows stripping the inner jacket approximately 6 inches from the end, leaving about 1/2 inch of the inner jacket covering the core.

Step 6: Prepare Bus Wires

Diagram shows cutting the inner core at the end. The inner core material is rolled back with pliers and separated from the bus wires.

Step 7: Re-twist Bus Wires

Diagram shows removing core material from the bus wires and re-twisting the bus wires.

Step 8: Install Heat-Shrink Tubes on Bus Wires

Diagram shows installing two 1/8" x 5½" heat-shrink tubes over the bus wires.

Heat-shrink the tubes into position, keeping the heat source moving from side to side.

Step 9: Install Larger Heat-Shrink Tube

Diagram shows installing a black 1/2" x 1½" heat-shrink tube over the previous tubes and the cable jacket.

Step 10: Seal Bus Wire Junction

Diagram shows pinching the hot heat-shrink tube with pliers between the bus wires to seal it, holding for 10 to 15 seconds.

Step 11: Install Braid Heat-Shrink Tube

Diagram shows slipping a green/yellow heat-shrink tube over the braid and shrinking it.

Step 12: Position Sealing Fitting

Diagram shows sliding the sealing fitting components into position at the core sealer.

Step 13: Install Sealing Fitting into Junction Box

Diagram shows installing the sealing fitting into a junction box.

Step 14: Insert Cable into Fitting

Diagram shows inserting the heating cable through the sealing fitting and tightening the components into place.

Step 15: Connect Leads

Connect heating cable leads to power wire leads (ground braid pigtail to ground wire).

Step 16: Install Cover

Install weathertight cover.

End Seal Instructions

Tools Required

• Diagonal cutters
• Needle-nose pliers
• Utility knife
• Heat gun or propane torch

Step 1: Strip Inner Jacket

Diagram shows stripping the inner jacket as shown. A note indicates "Do not cut into inner jacket."

Step 2: Trim Ground Braid

Diagram shows unraveling the ground braid and trimming it at the outer jacket, then cutting it back.

Step 3: Apply First Heat-Shrink Tube

Diagram shows heat-shrinking a 1½" heat-shrink tube in place with 3/8" over the end of the heating cable. The heat is removed, and the end is squeezed with needle-nose pliers for 10 to 15 seconds.

Step 4: Apply Second Heat-Shrink Tube

Diagram shows heat-shrinking a 4" heat-shrink tube in place with 3/8" over the end of the smaller heat-shrink tube. Heat is removed, the end of the smaller tube is re-squeezed, and then the end of the outer heat-shrink tube is squeezed. Hold for 10 to 15 seconds.