nvent RAYCHEM WM2-0235 WinterGard Mesh Instruction Manual

nvent RAYCHEM WM2-0235 WinterGard Mesh

Specifications

• Product Name: WinterGard Mesh Surface Snow Melting System
• Manual Languages: English (EN), French (CF)
• Manufacturer: nVent

Product Information

General Information
The WinterGard Mesh Surface Snow Melting System is designed to melt snow and ice from surfaces, providing a safe and convenient solution for winter weather conditions.

Use of the Manual
This manual provides installation and operation instructions for the WinterGard Mesh Surface Snow Melting System. It is important to read and understand this manual before proceeding with the installation.

WinterGard Mesh Applications
The WinterGard Mesh can be used for various applications, such as driveways, walkways, stairs, ramps, and other outdoor surfaces prone to snow and ice buildup.

Safety Guidelines
Ensure proper safety precautions are followed during the installation and operation of the WinterGard Mesh system. This includes proper grounding, electrical connections, and adherence to local electrical codes.

Electrical Codes
Before installation, familiarize yourself with the applicable electrical codes in your area to ensure compliance.

Approvals
The WinterGard Mesh Surface Snow Melting System has received relevant approvals and certifications to ensure its safety and performance. Refer to the product documentation for more information.

Warranty
The WinterGard Mesh Surface Snow Melting System is covered by a warranty. Refer to the warranty documentation for details on coverage and terms.

WinterGard Mesh Catalog Numbers
Refer to the WinterGard Mesh catalog numbers provided in the product documentation for ordering and identifying the required parts and equipment.

Required Parts & Equipment
Spacer, Junction Box, Supply Lead, and Caution Sign
The WinterGard Mesh system requires the following components for installation:

• Spacer
• Junction Box
• Supply Lead
• Caution Sign

These components are essential for proper installation and safety.

Controller
The WinterGard Mesh system requires a controller for proper operation. The controller is responsible for regulating the power supply to the heating elements. Refer to the product documentation for specific controller requirements.

Panels
The WinterGard Mesh system consists of panels that contain the heating elements. These panels are installed on the surface to be snow-melted. Refer to the product documentation for information on panel sizes and quantities required for your specific application.

Conduits
Conduits are used to protect and route the electrical cables connecting the panels, controller, and power supply. Proper conduit installation is essential for electrical safety and system performance.

Frequently Asked Questions (FAQ)

1. Q: Can I install the WinterGard Mesh system myself?
   A: While installation of the WinterGard Mesh system can be done by a competent DIY enthusiast, it is recommended to hire a professional electrician to ensure proper electrical connections and compliance with local electrical codes.

2. Q: Can the WinterGard Mesh system be used on all types of surfaces?
   A: The WinterGard Mesh system can be used on various surfaces, including driveways, walkways, stairs, ramps, and more. However, it is important to ensure that the surface is suitable for installation and that the system is properly sized for the specific application.

3. Q: How long does it take for the WinterGard Mesh system to melt snow and ice?
   A: The time required to melt snow and ice depends on several factors, including the temperature, thickness of the snow or ice, and the size of the installed system. It is recommended to allow sufficient time for the system to effectively melt the snow and ice.

4. Q: Is the WinterGard Mesh system energy-efficient?
   A: The WinterGard Mesh system is designed to provide efficient snow melting while minimizing energy consumption. The system includes advanced controls and sensors to optimize energy usage based on weather conditions and surface temperature.

IMPORTANT SAFEGUARDS AND WARNINGS

WARNING: FIRE AND SHOCK HAZARD
nVent RAYCHEM WinterGard Mesh Surface Snow Melting Systems must be installed correctly to ensure proper operation and to prevent shock and fire. Read these important warnings and carefully follow all installation instructions.

• Minimum installation temperature of the WinterGard Mesh Surface Snow Melting System is 23°F(-5°C).
• WinterGard Mesh Surface Snow Melting System is rated weather resistant and suitable for installations in wet areas (-WS).
• Approvals and performance of the WinterGard Mesh Surface Snow Melting systems are based on the use of approved components and accessories.
• To avoid damage to the heating system, do not energize it until it has been completely embedded and the installation has been completed.
• 30mA ground fault equipment protection must be used on each branch circuit with this heating system in order to minimize the danger of fire and to comply with the requirements of nVent warranties, agency certifications, and national electrical codes. Arcing may not be stopped by conventional circuit protection.
• Heating wires must be spaced at least 1/2 in (1.3 cm) from any combustible surface.
• Minimum bending radius of the heating wire is 3” (7.6cm).
• The heating wire must not touch, cross over, or overlap itself.
• De-energize the heating system before installation or servicing.
• The heating system must be properly grounded according to applicable electrical codes.
• Terminations must be kept dry before, during, and after installation.
• Damaged heating systems can cause electrical arcing or fire. If heating wires or terminations are damaged, they must be repaired or replaced. Contact nVent customer service for assistance.
• Rebar, wire mesh or other conductive materials used to support the heating system or to sit above it must be grounded in accordance with CSA Standard C22.1, Section 10 or the National Electrical Code as applicable.
• Megohmmeters operate at high voltage. This voltage is hazardous and possibly lethal. Read and follow all instructions included with the instrument you are using.
• Do not install the WinterGard Mesh Surface Snow Melting system in heavily trafficked commercial areas.

GENERAL INFORMATION

Use of the Manual
This manual covers the installation procedures, testing, and maintenance for nVent RAYCHEM WinterGard Mesh Snow Melting Systems, accessories, and controls for surface snow melting in concrete, asphalt, and sand or limestone screenings under paving stones*. This manual assumes that a proper snow melting or anti-icing design has been completed according to nVent’s recommendations. Only the applications described in this manual are approved by nVent for nVent RAYCHEM WinterGard Mesh Surface Snow Melting Systems and only when used with approved accessories. The instructions in this manual and the installation instructions included with the control systems, power distribution systems, and accessories must be followed for the nVent warranty to apply. For design assistance, technical support, or information regarding other applications not shown here, please contact your nVent representative or nVent directly.
nVent
7433 Harwin Drive Houston, TX 77036 USA

• Tel +1.800.545.6258
• Fax +1.800.527.5703
• Email: thermal.info@nVent.com

nVent.com/RAYCHEM
Important: For the nVent warranty and agency approvals to apply, the instructions that are included in this manual and product packages must be followed.

•  Special permission for paver snow melting is required from the Authority Having Jurisdiction.

WinterGard Mesh Applications
Surface Snow Melting: Surface snow melting systems prevent the accumulation of snow on ramps, slabs and driveways under typical snow conditions.
Anti-Icing: Anti-icing systems keep the surface temperature above freezing to prevent ice formation.

Safety Guidelines
As with any electrical equipment, the safety and reliability of any 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 components could damage the Surface Snow Melting System and may result in inadequate snow melting, 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.

Pay special attention to the following:

• Important instructions are marked Important
• Warnings are marked WARNING

Electrical Codes
Article 426 of the National Electrical Code (NEC) and Section 62 of the Canadian Electrical Code (CEC) govern the installation of fixed outdoor surface snow melting and de-icing systems. All installations must be in compliance with these and any other applicable national and local codes.

Approvals
WinterGard Mesh systems are approved for use in non-hazardous areas only.

Warranty

nVent warrants all nVent RAYCHEM WinterGard Mesh Systems against faulty workmanship and use of defective materials for two (2) years from the date of purchase. This warranty can be amended only by a written instrument signed by a duly authorized officer of nVent. Buyer’s exclusive remedy under this warranty shall be to have nVent, within a reasonable time, repair such goods, or supply replacement goods, or credit Buyer’s account for such goods and accept their return, whichever nVent may elect at its sole discretion. nVent shall in no event be liable for the cost of removal or installation, for loss or damage to or loss of use of facilities or other property, loss of revenue, loss of use of revenue, loss of anticipated profits, or other damages or costs of any kind whatsoever, whether direct, indirect, incidental, or consequential. Notwithstanding the foregoing, nVent shall have no liability whatsoever unless:

• Buyer promptly notifies nVent in writing after discovery of an alleged nonconformity and includes a detailed explanation of the alleged nonconformity;
• Buyer promptly returns the goods to nVent postage prepaid, at the address obtained by calling Customer Service at 1-800-545-6258 or 650-216-1526; and
• nVent examination of such goods establishes to nVent satisfaction that such alleged nonconformities actually exist and occurred in the cause of proper and normal use and were not caused by accident, misuse, neglect, alteration or improper installation, repair or testing or such other cause outside of the responsibility of nVent under this Limited Warranty.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER REPRESENTATIONS, WARRANTIES, OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT, AND OF ANY OTHER OBLIGATION OR LIABILITY ON THE PART OF nVent, WHETHER BY STATUTE, CONTRACT, STRICT LIABILITY, TORT OR OTHERWISE. If the goods are a consumer product in buyer’s jurisdiction, the above exclusion or limitation of incidental or consequential damages and the above disclaimer of implied warranties may not apply. The term of any such implied warranty is limited to the term of this two-year Limited Warranty. Some jurisdictions do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply. This warranty gives consumers specific legal rights, and consumers may also have other rights, which vary by jurisdiction.

WinterGard Mesh Catalog Numbers

The catalog number for WinterGard Mesh encodes the product characteristics as follows:
WM[a]-[bb][cc]

• WM = WinterGard Mesh
• [a] = Voltage
  • 1 = 120 V
  • 2 = 240 V
• [bb] = Width (ft)
  • 02 = 2 ft
  • 03 = 3 ft
• [cc] = Length (ft)
  • 05 = 5 ft
  • 10 = 10 ft
  • 15 = 15 ft
  • 20 = 20 ft
  • 25 = 25 ft
  • 30 = 30 ft
  • 35 = 35 ft
  • 40 = 40 ft
  • 45 = 45 ft
  • 50 = 50 ft
  • 60 = 60 ft
• Area coverage (ft2) = Width x Length
• Power (W) = Area coverage (ft2) x 50 W/ft2

For example, WM1-0205 is 120 Volts, 2 ft wide, 5 ft long, 10 ft2 area, and 500 Watts.

REQUIRED PARTS & EQUIPMENT

Spacer, junction box, supply lead and caution sign
When it is necessary to loosen the heating wire from the mesh, the plastics strips (Model EM2-SPACER-PL) will help maintain the correct spacing 3” (7.6 cm). For asphalt layer the metal spacer (Model HARD-SPACER-GALV-25MM-25M) should be used. Extension of the cold leads needs to be done in a junction box. The connection between the control panel and the junction box is made by a suitable supply lead. For installation in asphalt, the sensor cables must be protected by a metal conduit pipe or be laid under the asphalt layer in the substrate underneath. The conduit pipe is sealed at the end so the asphalt cannot seep in. Ensure that the heating wire and the splice and end seal terminations are completely enveloped by the asphalt without air pockets. Allow asphalt to cool to temperature of 212°F (100°C) or lower before pouring it within 30″ (76 cm) of the terminations. This work needs to be done before the asphalt pouring of the entire surface will be executed. Minimum one snow melt caution sign (Model SMCS or SMCS-CF) should be used per system.

Controller and Sensors
nVent offers control units specially designed for the surface snow melting application. Some incorporate combined temperature and moisture sensors to ensure efficient operation of the system.

Conduits
Minimum 3/4″ diameter conduits (not included) are required to protect the cold lead and the sensor connection lead.

Ground Fault Protection
Use circuit breakers that incorporate 30-mA ground-fault circuit protection, or provide equivalent levels of ground-fault protection. To minimize the danger of fire from sustained electrical arcing if the heating wire is damaged or improperly installed, and to comply with the requirements of nVent 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 protection.

Storage of WinterGard Mesh
Storage temperature range: -40°F to 113°F (-40°C to 45°C). Store all system elements in a clean, dry place.

Test equipment

• Ohmmeter
• 2500 Vdc megohmeter

INSTALLATION GUIDELINES & PROCEDURES

Area to be heated
Determine the exact area to be heated and consider the following factors:

• Ensure the area to be heated complies with the data in the design instructions. See Table 1 on page 10 for product selection.
• Establish junction box location(s) and ensure the connection leads (16.4′ (5 m)) are long enough.
• Inspect and clean the surface before installation, removing sharp objects that can damage the heating element.
• The heating element must not be shortened or altered.

Example of Snow Melting for a Parking Ramp

Preparing the Subsurface
WinterGard Mesh should be installed on a stable subsurface. In suspended structures, the top surface may consist of finished slabs, prestressed concrete or a suspended structure with poured concrete. WinterGard Mesh can be laid on all sub surfaces such as soil, compacted screens, sand, or gravel. In the case of poured concrete, ensure that the subsurface is smooth and all sharp objects are removed. Ramps on a solid subsurface do not require additional thermal insulation. Appropriate preparations should be made for installing the temperature and moisture sensor.

Conductor Resistance and Insulation Resistance Tests
Test WinterGard Mesh by measuring the conductor resistance and the insulation resistance. Test the conductor resistance with an ohmmeter. The measured resistance should be within -5% to +10% of the nominal resistance values shown in Table 1 on page 10.

Test the insulation resistance (using a megohmmeter) at three voltages: 500, 1000 and 2500Vdc. The reading should be 100 Mohms or higher.

Record all measured values on the Installation and Inspection Record provided in Section 7.

WinterGard Mesh Product Selection

Catalog #| Voltage (V)| Width (ft)| Length (ft)| Area (ft 2 )| Resistance (Ω)| Power (W)
---|---|---|---|---|---|---
WM1-0205| 120| 2| 5| 10| 28.8| 500
WM1-0210| 120| 2| 10| 20| 14.4| 1000
WM1-0215| 120| 2| 15| 30| 9.6| 1500
WM1-0220| 120| 2| 20| 40| 7.2| 2000
WM1-0225| 120| 2| 25| 50| 5.8| 2500
WM1-0230| 120| 2| 30| 60| 4.8| 3000
WM1-0310| 120| 3| 10| 30| 9.6| 1500
WM1-0315| 120| 3| 15| 45| 6.4| 2250
WM1-0320| 120| 3| 20| 60| 4.8| 3000
WM2-0205| 240| 2| 5| 10| 115.2| 500
WM2-0210| 240| 2| 10| 20| 57.6| 1000
WM2-0215| 240| 2| 15| 30| 38.4| 1500
WM2-0220| 240| 2| 20| 40| 28.8| 2000
WM2-0225| 240| 2| 25| 50| 23.0| 2500
WM2-0230| 240| 2| 30| 60| 19.2| 3000
WM2-0235| 240| 2| 35| 70| 16.5| 3500
WM2-0240| 240| 2| 40| 80| 14.4| 4000
WM2-0245| 240| 2| 45| 90| 12.8| 4500
WM2-0250| 240| 2| 50| 100| 11.5| 5000
WM2-0260| 240| 2| 60| 120| 9.6| 6000
WM2-0310| 240| 3| 10| 30| 38.4| 1500
WM2-0320| 240| 3| 20| 60| 19.2| 3000
WM2-0325| 240| 3| 25| 75| 15.4| 3750
WM2-0330| 240| 3| 30| 90| 12.8| 4500
WM2-0340| 240| 3| 40| 120| 9.6| 6000

WinterGard Mesh Installation

All connections and electrical testing should be carried out by a qualified electrician.

• For irregularly shaped areas, it is acceptable to cut the mesh and adjust the heating element position in order to achieve good coverage. See illustrative examples on page 13.
• The heating element must not be cut or damaged
• The heating element must not be crossed over itself
• The heating element must not be installed within 3” (7.6cm) of another section of heating element or 1″ from the cold leads
• WinterGard Mesh must not be installed across expansion joints, across separate concrete slabs. Crack control joints may be crossed as shown in the figure.

Minimum wire spacing is 3” (7.6cm)

• Maximum exposure temperature for WinterGard Mesh: 221°F (105°C) (for asphalt pouring, short term exposure up to 464°F (240°C) is allowed).
• The mesh must be secured to the underlaying surface to prevent movement during the installation. The cold lead cable must be protected in a conduit. The entire length of heating wire should be covered by wet sand-cement mixture, concrete, limestone screening, dry sand, or asphalt depending on the selected top surface.

Installation Overviews

Installation in concrete or asphalt

Installation under pavers

For installation under pavers (stone or brick), ensure that there is a solid base of 4” to 8” (102 mm to 203 mm) of crushed rock aggregate base and that it is tamped down and prepared for the mortar pour. The sand or concrete layer directly above WinterGard Mesh should be hand tamped only.
IMPORTANT: Do not use sand for sloping areas since the sand will be washed away, resulting in damage to the heating wire.

WARNING: Do not use any heavy equipment, machinery, or vehicles on top of an exposed WinterGard Mesh system.

• If the heating element needs to be loosened from the mesh to achieve good coverage, the installer should use spacers to keep the heating element spacing consistent.

• Step 1: Install the sensor lead

  • The sensor lead should be routed through a conduit in the layer below the heating system.

• Step 2: Make provisions for installation of the temperature/moisture sensor

  • For sensors comprising a separate housing and sensor, install only the housing at this stage. For sensors without a separate housing, use a spacer the same size as the sensor (such as a wooden block) to create a void for the sensor to be installed into later. The sensor housing or spacer should be placed mid-way between heating elements in an open area, away from trees, bushes, or other obstructions that would prevent precipitation from falling directly on the sensor. Support the sensor housing or spacer so that it will be vertical and level with the lowest point of the adjacent surface.

• Step 3: Complete the layer below the heating system

  • Install the subsurface materials in accordance with applicable building and electrical codes.

• Step 4: Perform Conductor Resistance and Insulation Resistance Tests as described in section 3.3
  • Carry out the resistance tests on each circuit to ensure the product is within spec prior to installation. Record the values for each circuit on the Installation and Inspection Record.
• Step 5: Install WinterGard Mesh throughout the heated area

• Step 6: Inspect the heating system

  • Visually check the heating system for damage.
  • Verify that any loose heating cable is secured with spacers.
  • Verify that the correct cable spacing of 3” (7.6 cm) has been maintained and that the heating cable is being kept away from sharp edges and not crossing expansion joints or across separate slabs. If applicable, verify that the heating cable is protected when crossing a crack control join.
  • Verify that the heating system is installed at the correct depth throughout the heated area.
  • Inspect the connection leads for correct installation.

• Step 7: Complete a detailed sketch of the layout

  • Record the layout of each circuit, with particular reference to the position of the connection leads. Document the installation with photos.

• Step 8: Perform conductor resistance and insulation resistance tests as described in section 3.3

  • Perform the resistance tests on each circuit to detect any damage that may have occurred during installation.
  • Record the values for each circuit on the Installation and Inspection Record in Section 7.

• Step 9: Install the surface materials

  • Install concrete, asphalt, or pavers in accordance with applicable building and electrical codes.

• Step 10: Perform conductor resistance and insulation resistance tests as described in section 3.3

  • Perform the resistance tests on each circuit to detect any damage that may have occurred after installation. Record the values for each circuit on the Installation and Inspection Record in Section 7.

• Step 11: Connect and install the moisture sensor if applicable

  • Install the moisture sensor in accordance with the manufacturer’s instructions. Ensure the sensor is mounted vertically and supported at the correct height so the top of the sensor is level with the lowest adjacent surface.

• Step 12: Connect and install the temperature sensor if applicable

• Step 13: Complete wiring and install control and monitoring equipment
  • Install panels, control units, thermostats and manual control equipment in accordance with the manufacturers’ instructions.
• Step 14: Perform final system inspection and tests
  • Inspect all wiring for conformance to design drawings.
  • Verify that all protection devices have the correct rating.
  • Perform controller checks in accordance with the manufacturer’s instructions.
  • Complete required testing in accordance with applicable building and electrical codes.
• Step 15: Documentation
  • The installer must supply the operator/owner with the layout drawing and a copy of the Installation and Inspection Record.

SYSTEM OPERATION
Operate the system in accordance with the control and monitoring instructions.

SYSTEM MAINTENANCE
The system has no moving parts and therefore requires minimum maintenance. Refer to and comply with applicable codes and requirements for the maintenance of electrical equipment. Test all ground-fault breakers per manufacturer’s instructions. Periodically inspect the system controls by operating them to ensure that they function correctly.

SYSTEM TROUBLESHOOTING

Trouble Shooting Guide
WARNING: Disconnect all power before working on any part of the electrical system.

IMPORTANT: If the corrective actions above do not resolve the problem, contact your nVent representative for further assistance.

INSTALLATION AND INSPECTION RECORD

North America

• Tel +1.800.545.6258
• Fax +1.800.527.5703
• Email: thermal.info@nVent.com

Europe, Middle East, Africa

• Tel +32.16.213.511
• Fax +32.16.213.604
• Email: thermal.info@nVent.com

Asia Pacific

• Tel +86.21.2412.1688
• Fax +86.21.5426.3167
• Email: cn.thermal.info@nVent.com

Latin America

• Tel +1.713.868.4800
• Fax +1.713.868.2333
• Email: thermal.info@nVent.com

©2023 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.
RAYCHEM-IM-H61652-WinterGardMesh-ML-2210
nVent.com/RAYCHEM

References

• Electrical Heat Tracing | Heat Tracing | nVent RAYCHEM

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