Raychem H900 WinterGard Power Connection Kit with End Seal Installation Instructions

Product Overview

The Raychem WinterGard power connection kit (H900) is designed for use with WinterGard heating cables: H311, H611, H612, H621, and H622. It facilitates water-pipe freeze protection and can also be used for roof and gutter de-icing applications with specific cable types (H612 and H622). This kit is not intended for use with aluminum feed wires.

For technical support, contact Chemelex at (800) 545-6258.

Kit Contents

The kit includes components for one power connection and one end seal:

Tools Required

• Needle nose pliers
• Pen
• Propane torch or heat gun
• Diagonal cutters
• Utility knife
• Panduit CT100 crimp tool
• Adjustable wrench
• Screwdriver

Additional Materials Required

• UL Listed or CSA Certified junction box suitable for the location, with a clearance hole for 1½-inch conduit or ½-inch NPT threaded hub.
• For H311, H611, and H621, a metallic junction box must be used to ensure proper grounding.
• Additional WinterGard accessories may be required, such as H903 application tape for pipe applications, and H913/H914 roof clips or H915 downspout hangers for roof and gutter de-icing applications.

Important Safety Warnings

WARNING: These components are electrical devices and must be installed correctly to prevent shock or fire. Always follow installation instructions and heed warnings.

• Ground-fault equipment protection is required on each heating cable branch circuit to minimize fire risk from arcing.
• Component approvals and performance are based on 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.
• Keep components and heating cable ends dry during installation.
• Damaged bus wires can overheat or short. Do not break braid or bus wire strands when scoring the jacket or core.
• Bus wires will short if they contact each other; keep them separated.
• Use a heat gun or torch with a soft, yellow, low-heat flame, not a blue focused flame. Avoid overheating, blistering, or charring heat-shrinkable tubes.
• Use only fire-resistant insulation materials like fiberglass wrap.
• Leave these instructions with the user.

CAUTION: Charring or burning heat-shrinkable tubes can produce fumes causing irritation. Consult Material Safety Data Sheet RAY3122.

For emergency assistance, contact CHEMTREC at (800) 424-9300.

Heating Cable Selection and Design for Pipe Applications

Ensure the heating cable is suitable for your application. Refer to the Commercial and Residential Application and Design Guide (H53585) for more information.

1. Determine the heating cable type:

Use Table 1 (metal pipes) and Table 2 (plastic pipes) to select the appropriate heating cable based on pipe size, lowest air temperature, and insulation thickness. The tables indicate whether to use straight or spiraled tracing and provide a spiraling ratio (feet of heating cable per foot of pipe).

Example 1: Pipe size: 1 in, Lowest air temp.: 0°F, Insulation thickness: ½ in

Example 2: Pipe size: 2½ in, Lowest air temp.: -20°F, Insulation thickness: ½ in

If the spiraling ratio is 2.0, use two straight traces at 4 and 8 o'clock positions. If the ratio is 3.0, use three straight traces at 11/1 o'clock, 4 o'clock, and 8 o'clock positions.

2. Calculate the total heating cable length required:

Use the formula: Length = A + B + C + D + E + F + G + H, where:

• A = Pipe length x spiraling ratio
• B = 4 ft x # gate/globe valves x valve length (ft) x spiraling ratio
• C = 2 ft x # ball/butterfly valves x valve length (ft) x spiraling ratio
• D = 2 ft x # flanges x pipe diameter (ft) x spiraling ratio
• E = 2 ft x # pipe supports x pipe diameter (ft) x spiraling ratio
• F = 1 ft for each power connection
• G = 2 ft for each splice connection
• H = 3 ft for each tee connection

Example Calculation: Pipe length: 50 ft, Spiral ratio: 1.3, 3 globe valves (0.5 ft each), 10 pipe supports, 1 power connection, 1 splice connection.

Total WinterGard heating cable required: 78.0 ft

3. Determine the maximum heating cable circuit length allowed:

Refer to Table 3 for maximum circuit lengths based on heating cable type, circuit breaker rating, and start-up temperature. Ensure circuits do not exceed these limits.

Heating Cable Installation for Pipes

1. Prepare for installation:

• Store heating cable in a clean, dry place.
• Complete piping pressure test.
• Verify all WinterGard heating cable and accessories are available.
• Plan the routing of the heating cable on the pipe.

2. Cut the heating cable to length:

Cut to the required length, leaving a minimum of 1 foot extra for power connection. For splices and tees, leave 1 foot extra per section. Cutting does not affect heat output.

Protect exposed cable ends from moisture and damage.

3. Position and attach heating cable to pipe:

• Ensure piping is dry.
• Install using straight, spiraling, or multiple tracing as per the design section. For straight tracing, use the 4 or 8 o'clock positions.
• For spiraling, suspend loops every 10 feet. Use the spiral factor from Table 1 or 2 to determine loop length (e.g., 1.3 factor means a 13-foot loop for every 10 feet of pipe).
• Secure the heating cable flat to the pipe using glass tape to ensure good contact.
• Tape the heating cable to the pipe at 2-foot intervals using Raychem H903 fiberglass application tape or nylon cable ties. Do not use vinyl electrical tape, duct tape, metal bands, or wire.

4. Install heating cable end seals, splices, tees, and power connection:

Install these components before plugging in. Use H910 WinterGard Splice and Tee Kit for splicing and teeing.

5. Check the installation:

• Before installing thermal insulation, check for mechanical or thermal damage to the heating cable.
• Visually inspect power connections, end seals, splices, and tees.
• Test each circuit with a megohmmeter as per the "Heating cable testing and maintenance" section.

6. Install thermal insulation:

Ensure insulation is properly installed and weatherproofed. Follow information in heating cable selection tables and insulate all pipe work.

7. Mark the installation:

Place "Warning" labels on the insulation surface at 10-foot intervals to indicate the presence of electric heating cable.

8. Check the installation (final):

• Before powering, check for mechanical damage (cuts, clamps, etc.).
• Visually check power connections, end seals, splices, and tees.
• Test each circuit with a megohmmeter.

Electrical Protection

Voltage Ratings:

• H311, H611, H612: 110-120 Vac
• H621, H622: 208-240 Vac

Ground Fault Protection: Ground-fault equipment protection (e.g., 30-mA trip level circuit breakers like Square D QO-EPD) is required on each heating cable branch circuit by Chemelex and national electrical codes to reduce the risk of fire.

Heating Cable Testing and Maintenance

Chemelex recommends checking insulation resistance using a 2500-Vdc megohmmeter during installation. Minimum reading should be 1000 megohms.

Record original values and compare with subsequent readings during maintenance. If readings fall below 1000 megohms, inspect cables and insulation for damage. Replace damaged sections using approved WinterGard H910 splice kits. Do not repair damaged cable. If no physical damage is found, replace the entire circuit.

WARNING: Damaged heating cable or components can cause electrical shock, arcing, and fire. Do not energize damaged components. Replace immediately.

Heating Cable Design for Roof and Gutter De-Icing

Only WinterGard Wet H612 (120-V) and H622 (240-V) heating cables are suitable for the H900 kit in roof and gutter de-icing applications.

1. Calculate the heating cable length required:

Use the formula: Length = A + B + C + D + E + F + G, where:

• A = Roof edge length (ft) x feet of heating cable per foot of roof edge (Table 5)
• B = Roof edge length (ft) x 0.5* (for roof extension)
• C = Total gutter length (ft)
• D = Total downspout length (ft) + 1 ft
• E = 1 ft for each power connection
• F = 2 ft for each splice connection
• G = 3 ft for each tee connection

Example Calculation: Roof edge: 40 ft, Roof overhang: 1 ft, Roof gutter: 40 ft, Downspout: 15 ft, 2 power connections, 1 tee connection.

Total WinterGard Wet heating cable required: 161 ft. Note: This may require two separate circuits if exceeding 100-ft maximum circuit length (Table 6).

Roof and Gutter Installation

1. Prepare for installation:

• Store heating cable in a clean, dry place.
• Use only specified Raychem accessories: H900 kit, H910 Splice and Tee Kit, H915 Downspout Hangers, H913/H914 Roof Clips.
• Plan heating cable routing for roof and gutter de-icing.
• Ensure gutters and downspouts are clear of debris.

2. Cut the heating cable to length:

Cut to length, leaving 1 foot extra for power connections, splices, and tees. Protect exposed ends.

3. Position and attach the heating cable:

On roofs:

• Loop heating cable on roof overhang. Connect bottom of loops to cable in gutter for drainage.
• Extend top of loops beyond wall-roof joint. Use 2-foot clip-spacing along roof edge (see Table 5 for spacing).
• Use WinterGard H913/H914 roof clips for attachment. Reseal nail/screw holes if necessary.
• For flat roofs, space cable as needed for runoff. Use single-ended clips at 3-foot intervals.
• A barrier (snow fence) can be placed above the cable to prevent damage from ice slides.

In gutters and downspouts:

• Run cable along gutters and into downspouts, ending below the freezing level.
• Loop cable in downspouts if convenient or use H910 kit to tee downspout.
• Use WinterGard H915 downspout hangers for protection and strain relief.
• Use H913/H914 roof clips to route cable into/out of gutters to prevent abrasion.
• Protect cable protruding past downspout openings.

4. Install heating cable end seals, splices, tees, and power connection:

Install prior to plugging in. Follow H900 kit instructions. Use only weatherproof junction boxes for wet locations.

5. Mark the installation:

Apply the "Electric De-icing" label to the junction box cover.

6. Check the installation:

• Check for mechanical damage (cuts, clamps, etc.).
• Visually check power connections, end seals, splices, and tees.
• Test each circuit with a megohmmeter.

H900 Power Connection Kit Assembly

Detailed step-by-step instructions with diagrams are provided for assembling the power connection and end seal for different heating cable types (H311, H611, H621 and H612, H622).

Key steps include:

• Identifying the heating cable type (braid and no outer jacket vs. braid and outer jacket).
• Preparing the cable ends by scoring, peeling jackets, and manipulating the braid.
• Applying heat-shrinkable tubes for insulation and sealing.
• Connecting to the power source via a junction box, ensuring proper grounding and sealing.

Limited Warranty

Chemelex warrants Raychem heating cables and components against faulty workmanship and defective materials for two (2) years from the date of purchase. This warranty is subject to specific terms and conditions, including prompt notification of nonconformities and return of goods. Chemelex is not liable for installation/removal costs, loss of revenue, or consequential damages. Some jurisdictions may have different consumer rights regarding implied warranties and consequential damages.