E-100 LA Installation Manual

E-100-L-A
High-Profile LIGHTED End Seal Installation Instructions
Description
The E-100-L-A is a Type 4X-rated end seal kit with a light that indicates
voltage at the end of the circuit. It is designed for use with Raychem BTVCR, BTV-CT, QTVR-CT, XTV-CT, KTV-CT, and VPL-CT industrial parallel
heating cables. Once installed, the end seal is easily re-entered for
maintenance and the heating cable can be accessed without removing the
end seal. The LED indicator light provides excellent visibility.
This kit may be installed at temperatures as low as –40°F (–40°C). For
easier installation store above freezing until just before installation.
Kit is rated for 100 to 277 V.
Make sure voltage rating of light is the same as that of the heattracing circuit.
For technical support call Pentair Industrial Heat Tracing Solutions at
(800) 545-6258.
Tools Required
• Wire cutters
• Utility knife
• Needle nose pliers
• Slotted screwdriver or nutdriver
• Panduit CT-100 crimp tool or equivalent
Approvals
Additional Materials Required
Hazardous Locations
– WS
Class I, Div. 2, Groups A, B, C, D
Class II, Div. 1 and 2, Groups E, F, G
Class III
CLI, ZN1, AEx e mb IIC T* Gb(1)
ZN21 AEx tb IIIC T*
Ex e mb IIC T* Gb
Ex tb IIIC T***°C Db
Ex em IIC T* Gb
IECEx SIR 14.0007X
Ex e mb IIC T* Gb IP66
Ex tb IIIC T***°C Db
• Pipe strap
• GT-66 or GS-54 glass cloth tape
Optional Materials
• Small pipe adapter for 1 in (25 mm) and smaller pipes:
Catalog number JBS-SPA P/N E90515-000
(1)
Except VPL
Except KTV-CT
* For system Temperature Code, see heating cable or design documentation.
(2)
Leash
Strain relief
Kit Contents
B
ItemQty Description
A
1
End seal stand and light assembly
B
2
Insulated parallel crimps
C
1
End seal label
D
1
Cable lubricant
E
1
Cable tie
F
1
Core sealer
Light
A
Stand
C
D
F
WARNING:
E
CAUTION:
This component is an electrical device that must be installed correctly to
ensure proper operation and to prevent shock or fire. Read these important
warnings and carefully follow all of the installation instructions.
• To minimize the danger of fire from sustained ­electrical arcing if the
heating cable is damaged or improperly installed, and to comply with
the r­equirements of Pentair Industrial Heat Tracing Solutions, agency
certifications, and national electrical codes, ground-fault ­equipment
protection must be used. Arcing may not be stopped by conventional
circuit breakers.
• Component approvals and performance are based on the use of
Pentair Industrial Heat Tracing Solutions-specified parts only. Do
not use substitute parts or vinyl electrical tape.
• The black heating cable core and fibers are ­conductive 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.
• Keep components and heating cable ends dry before and during
installation.
• Bus wires will short if they contact each other. Keep bus wires
separated.
• Use only fire-resistant insulation materials, such as fiberglass wrap
or flame-retardant foam.
• Leave these installation instructions with the user for future use.
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Health Hazard: Prolonged or repeated contact with the sealant
in the core sealer may cause skin ­irritation. Wash hands thoroughly.
Overheating or burning the sealant will produce fumes that may cause
polymer fume fever. Avoid contamination of cigarettes or tobacco.
Consult MSDS VEN0033 for further information.
CHEMTREC 24-hour emergency telephone:
(800) 424-9300.
Non-emergency health and safety information:
(800) 545-6258.
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Heating Cable Types
Braid
Outer
jacket
Inner jacket
Heating element
Braid
Outer
Braid jacket
Outer
jacket
Inner jacket
Inner jacket
Bus wire connection
Clear jacket
Conductive fiber
Conductive core
Insulated bus wire
Spacer
Bus wire
VPL-CT
Bus wire
BTV-CR, BTV-CT, QTVR-CT
XTV-CT, KTV-CT
1
2
• Allow approximately 24 in (60 cm) of heating cable for
installation. For VPL, cut cable 12 in (30 cm) from bus
indentation.
• Optional: If stand is to be
installed on bottom side of
pipe, knock out drain hole
prior to inserting cable.
• Cut off heating cable end at about 45° for easier
insertion.
• Apply lubricant for easier
insertion into stand.
12 in
(30 cm)
24 in
(60 cm)
• Slide heating cable
through stand.
12 in
(30 cm)
• Square off cable end with
90° cut.
Drain hole
45°
Indentation (bus wire
connection on VPL
heating cables only).
3
4
• Determine heating cable type and continue as shown.
2 1/4 in
(57 mm)
XTV, KTV
Go to Step 5A
BTV, QTVR
Go to Step 5B
VPL
Go to Step 5C
• Measure exactly 2 1/4 in (57 mm).
• Lightly score outer jacket around and
down as shown.
• Bend heating cable to break jacket at
score; peel off jacket.
• Remove all exposed braid.
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5A
5B
XTV, KTV
BTV, QTVR
Do not cut bus wires
Do not cut bus wires
• Measure exactly
1 3/8 in (35 mm).
• Lightly score inner
jacket around and
down as shown.
• Measure exactly
1 3/8 in (35 mm).
• Lightly score inner
jacket around and
down as shown.
1 3/8 in
(35 mm)
1 3/8 in
(35 mm)
• Peel off jacket.
• Peel off jacket.
• Notch core.
1/4 in
(5 mm)
• Cut and remove all
fiber strands.
• Peel bus wire from core.
• Score and remove
center spacer.
• Remove any
remaining fiber
material from bus
wires.
• Score core between bus
wires at inner jacket.
• Bend and snap core.
• Peel core from bus wire.
• Remove any remaining core
material from bus wires.
Go to Step 6
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Go to Step 6
3/8
5C
VPL
Do not cut bus wires
• Measure exactly
1 3/8 in (35 mm).
• Lightly score inner
jacket around and
down as shown.
1 3/8 in
(35 mm)
• Peel off inner jacket.
• Unwind heating
­element, cut and
remove as shown.
• Lightly score clear
jacket around and
down as shown.
• Remove insulation
from ends of bus
wires.
1/2 in
(13 mm)
Go to Step 6
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6
7
Caution: Health Hazard. Wash hands after contact
with sealant. Consult material safety data sheet
VEN0033.
• Mark the jacket
as shown.
•If needed, re-twist and straighten
bus wires, then insert bus wires
into guide tubes as shown.
5/8 in
(15 mm)
Make sure all strands
go into the tubes.
8
9
• Push core sealer onto the heating
cable to the mark made in step 6.
• Remove the guide tubes and
dispose of them in a plastic bag.
Tubes
Note: Extra force may be required
for larger cables or at lower
temperatures.
Make sure the bus
wires do not kink,
bunch, or crossover.
10
11
• Pull cable back through end seal stand until braid is just
visible above strain relief.
1 3/4 in
(44 mm) Braid
Strain
relief
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1/2 in
(13 mm)
• Trim exposed
conductors.
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12
• Fasten end seal stand to pipe with pipe strap. Do not pinch
heating cable. Be sure pipe strap is under heating cable.
• Loop and tape extra heating cable to pipe. Minimum bend
radius is 3/4 in (20 mm).
Note: For 1-in
(25-mm) and smaller
pipes use adapter
(purchased
separately) between
stand and pipe.
JBS-SPA
adapter for
small pipes
Position
adapter this
side up.
13
Insulated
parallel
crimps
• Place blue crimps
onto bus wires.
• Crimp bus wires to
lead wires.
14
• Push excess wire
inside light.
•Tighten light onto end seal stand.
Be sure wires
are not caught
in threads.
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15
• Insert cable tie through the slot on stand and the slot on
the light, then tighten.
16
• Apply insulation and weather-seal the stand entry.
• Fasten end seal label to insulation.
• Leave these instructions with the end user for future
reference.
Trim
Weather seal
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Troubleshooting Guide
Problem
Troubleshooting steps
Light is dim
or off.
1. Check that light voltage rating matches supply voltage for heat-tracing circuit. Supply voltage lower or higher than light
rating will cause malfunctions.
2. Check that heat-tracing circuit is energized. Although the circuit breaker is on, control devices such as thermostats may
switch heating cable off.
3. Following electrical safety procedures, disconnect supply voltage, unscrew light from end seal base and check that crimp connections to heating cable bus wires are tight and not crossed or shorted. Loose c­ onnections or shorts will cause malfunctions.
4. With circuit off, attach volt meter leads to crimps. Energize circuit and measure voltage at light. Use the following table to
determine whether the voltage measured is within the acceptable range.
•If voltage at light is in acceptable range and connections are good, the light may be defective or ­damaged. Replace light.
•If there is no voltage at the light, there may be breaks in the heating cable between the power ­connection and the end
seal. Check for splice or tee connections that may be left open.
•If voltage at light is above specified limits, the light may be off. Voltages above specified range can damage light. Replace
light with correct version for line supply voltage or adjust supply voltage accordingly.
•If voltage at light is present but below specified limits, the light may be dim or off. The following table lists typical
causes for low voltages and possible solutions.
Cause
Supply voltage at start of circuit is low (light is designed
to work with supply voltages within 10% of nominal).
Heating cable length is too long (light is designed to
work with published maximum c­ ircuit lengths).
Heating cable is started under very cold c­ onditions
(heating-cable voltage drop is very high for first minutes
of very cold start-up).
Heating cable controller is reducing voltage (light may
not work with controllers that phase fire to reduce line
voltage).
Problem
Solution
Increase power wire gauge size to reduce voltage drop
between panel and heating cable power c­ onnection.
Split heating cable into multiple circuits. Shorten length
of heating cable.
Wait for heating cable to warm up. Voltage at light will
increase.
Turn off phase firing function in heating cable c­ ontroller.
Troubleshooting steps
Cap cannot be 1. Check that heating cable is installed and stripped correctly. The top of the insulated parallel crimps should be 2 3/8 in (60
tightened
mm), or less, above the top of the plastic strain relief in the stand.
completely.
2. Check that core sealer is positioned properly. The end of the core sealer must be flush against the plastic strain relief in
the stand.
3. Check that the threads on the light and stand are clean. The connection wires between the heating cable and the light
should not be caught in stand threads.
WWW.PENTAIRTHERMAL.COM
NORTH AMERICA
Tel:+1.800.545.6258
Fax:+1.800.527.5703
Tel:+1.650.216.1526
Fax:+1.650.474.7711
[email protected]
Europe, Middle East, Africa
Tel:+32.16.213.511
Fax:+32.16.213.603
[email protected]
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Tel:+86.21.2412.1688
Fax:+86.21.5426.2937
[email protected]
Latin America
Tel:+1.713.868.4800
Fax:+1.713.868.2333
[email protected]
Pentair, BTV, QTVR, XTV, KTV and VPL are owned by Pentair or its global affiliates. All other trademarks are the property of their respective owners.
Pentair reserves the right to change specifications without prior notice.
© 1997-2014 Pentair.
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