Danfoss 088L0023 User manual

Installation Instruction
Power connection kit
Cable to Junction Box with ½”NPT cable gland

Table of contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Certications / Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 Kit contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required tools / equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparation of the trace heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparation of the trace heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation of the heat shrink tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of the end seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Sécurité et avertissements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Overview
Cold applied connection system for use with a ½”NPT thread junction box Danfoss PX or
RX trace heaters.
Catalog No.: 088L0023.
This manual introduces the operation and installation of Danfoss heat shrink connection technology
for use with a ½”NPT thread junction box and the following self-regulating trace heaters:
• Danfoss PX Pipe Trace Heating System
• Danfoss RX-C Roof and Gutter De-Icing System
To connect the trace heater to the cold lead cable the 2 bus wires are insulated with heat shrink tubes,
then connected to the cold lead cable inside the junction box. Additionally, a green/yellow heat shrink
tube is provided to connect the twisted grounding braid to the grounding conductor. Finally, the end
of the trace heater is insulated by means of another heat shrink tube.
The following terms describe the parts of the trace heater within these instructions:
heating matrix
bus wire
insulation jacket
grounding braid
outer jacket
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2 Certications / Approvals
Heat shrink technology connection system for use with a ½”NPT thread junction box and
Danfoss PX/RX trace heaters
3 Technical data
Ambient temperature range - 4 °F to +185 °F /
-20 °C to +85° C
Max. operating temperature end cap 185 °F / 85 °C
Electrical data see specications of the trace heater used
4 Safety
For safe installation and operation of the cold applied connection system the technical requirements
and instructions given in this manual must be followed.
WARNING:
Risk of re or electrical shock. Follow these guidelines to avoid personal injury or material damage.
• All electrical systems and installations must comply with Danfoss requirements and be installed in
accordance with the relevant electrical codes and any other applicable national and local codes.
• The US and Canadian electrical codes require ground fault protection to be provided for all trace
heating circuits.
• Install the connection system and trace heaters carefully.
• Use the trace heater and connection system in accordance with the intended purpose and strictly
comply with the operational data specied in section Technical Data.
• The bending radius of the trace heater must be at least 1” (25 mm). Do not bend on the narrow axis.
• Any defective component of the kit must be replaced before installation.
• To avoid short circuits, do not connect the trace heater bus wires together.
• Keep all components and the trace heaters dry before and during installation.
• Beware of hot surfaces when using the heat gun.
• Keep these instructions for future reference. If applicable, leave them with the end user.
• De-energize before installation or servicing.
• Use only original accessories.
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5 Kit contents
The following table lists the kit contents for each of the heat shrink technology connection systems for
PX/RX trace heaters:
Power connection kit
2 x Heat shrink tube for bus wires (black) 1 x Heat shrink tube for grounding braid
(green/yellow)
1 x Outer heat shrink tube for bus wires (black) 3 x Terminal block
1 x Plastic gland body 1 x Inner heat shrink tube for end-termination
1 x Grommet 1 x Outer heat shrink tube for end-termination
1 x Fixing nut 1 x Terminal clamp
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6 Installation
Required tools / equipment
The following tools and equipment are required for installation of the connection system:
• Wire cutters
• Flat screwdriver
• Heat gun
• Utility knife
• Needle-nose pliers (2x)
• Tape measure
• 4”x 4” (or larger) UL Listed or CSA Certied junction box
with ½” NPT thread.
Preparation of the trace heater
WARNING:
Risk of re or electrical shock. De-energize all power circuits before installation or servicing. Always
use ground fault equipment within the heat tracing system.
• Double-check that all power circuits are de-energized before you begin your work.
• Make sure that you do not exceed the maximum heating circuit length for the trace heater type you
use. Refer to the system manual of the heating system
1
2
3 x
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Preparation of the trace heater
WARNING:
Risk of short cuts and material damage. Keep the trace heater ends dry before and during installation.
Observe the trace heater’s installation instructions.
Unroll the required trace heater in a straight line and cut to the correct length. Cut o the trace heater
ensuring a straight cut:
WARNING:
Risk of electrical shock and material damage. The gland body and grommet for PX/RX trace heaters
are slightly dierent. Make sure to use the cable gland kit that ts the trace heater you use.
Slide the xing nut, the grommet and the gland body onto the trace heater.
Remove 5 ¾”(145 mm) of the outer jacket on the end of the trace heater.
3
4
5
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Preparation of the trace heater
WARNING:
Risk of short cuts and material damage. Keep the trace heater ends dry before and during installation.
Observe the trace heater’s installation instructions.
Unroll the required trace heater in a straight line and cut to the correct length. Cut o the trace heater
ensuring a straight cut:
WARNING:
Risk of electrical shock and material damage. The gland body and grommet for PX/RX trace heaters
are slightly dierent. Make sure to use the cable gland kit that ts the trace heater you use.
Slide the xing nut, the grommet and the gland body onto the trace heater.
Remove 5 ¾”(145 mm) of the outer jacket on the end of the trace heater.
Push the grounding braid back. Use the screwdriver to form an eyelet. Be careful not to damage the
internal insulation jacket
Bend the trace heater and pull the heating element out of the grounding braid.
Twist the grounding braid in order to form a wire.
Push the green/yellow heat shrink tube (length: 4 ¾” (120 mm); diameter: ¼” (6 mm) onto the
twisted grounding braid.
Shrink the tube at a temperature of 275 °F / 135 °C.
6
7
8
9
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Remove 4 ½”(115 mm) of the internal insulation jacket.
Make a small cut over and under each bus wire. Take care not to damage the bus wires.
Carefully make an incision into the edges of the heating element. Take care not to damage the bus
wires.
Pull o the bus wires while holding the heating element.
10
11
12
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Remove any remaining heating element that sticks to the bus wires.
Twist the bus wires.
Remove the remaining heating element. Take care not to damage the bus wires.
Carefully cut in a triangle (⁄”(5 mm)) between the bus wires. Take care not to damage the bus
wires.
13
10
14
11
15
12
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Installation of the heat shrink tubes
Slide the bus wire heat shrink tubes (length: 4”(100 mm); diameter: ¼” (6 mm)) onto the bus
wires.
WARNING:
Risk of burns. Beware of hot surfaces when using the heat gun.
Shrink the tubes at a temperature of 275 °F / 135 °C.
Push the outer heat shrink tube (length: 1”(25 mm); diameter: ½” (12 mm)) over the end of the
trace heater.
Shrink the tube at a temperature of 275 °F / 135 °C.
While still hot, compress the tube between the bus wires using pliers and hold for 5 seconds.
16
17
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Cable connection
Feed the cables into the junction box and tighten the gland to a torque of 6 ft. lbs.
For powered splice and powered T connection kits repeat steps 3 to 16 to prepare the remaining trace
heaters, introduce them into the junction box and tighten the gland.
Feed the cold lead cable into the junction box.
↻6 ft. lbs.
16 18
19
17
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Inside the junction box, use the individual terminal blocks to connect the bus wires and the
twisted grounding braid / grounding conductor to each other. Make sure that the wires are fully
engaged in the terminal block.
Phases Neutral Ground
Establish all connections as shown in the following gure.
Mount the cover of the junction box according to the manufacturer’s installation instructions.
20
21
22
Power connection
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Installation of the end seal
Cut the trace heater o straight.
Remove ¾”(20 mm) of the outer jacket on the trace heater.
Remove the exposed grounding braid. Make sure that the insulation jacket is not damaged.
Cut in a triangle (¼”(5 mm)) between the bus wires.
Ground
20 23
24
25
21
22
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Put the inner heat shrink tube for the end-termination (length: ¾” (20 mm); diameter: ½” (12
mm)) over the end of the trace heater.
Leave an overlap of ⁄” (10 mm).
Beginning at the end of the cable, shrink the tube at a temperature of 275 °F / 135 °C.
While still hot, compress the end of the tube using pliers and hold for 5 seconds.
Now, put the outer heat shrink tube (length: 2 ¾” (70 mm); diameter: ¾” (19 mm)) over the
end of the trace heater.
Make sure that it overlaps the bared part of the trace heater for ¾”(20 mm).
Beginning at the end of the cable, shrink the tube at a temperature of 275 °F / 135 °C.
While still hot, press the end of the tube using pliers.
26
27
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Slide the terminal clamp over the overlapping end of the heat shrink tube.
Crimp on the terminal clamp using pliers.
Cut o the heat shrink tube in excess at ⁄” (2 mm) of the terminal clamp
26
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7 Safety
For safe installation and operation of the cold applied connection system the technical requirements
and instructions given in this manual must be followed.
WARNING:
Risk of re or electrical shock. Follow these guidelines to avoid personal injury or material damage.
• All electrical systems and installations must comply with Danfoss requirements and be installed in
accordance with the relevant electrical codes and any other applicable national and local codes.
• The US and Canadian electrical codes require ground fault protection to be provided for all trace
heating circuits.
• Install the connection system and trace heaters carefully.
• Use the trace heater and connection system in accordance with the intended purpose and strictly
comply with the operational data specied in section Technical Data.
• The bending radius of the trace heater must be at least 1”(25 mm). Do not bend on the narrow axis.
• Any defective component of the kit must be replaced before installation.
• To avoid short circuits, do not connect the trace heater bus wires together.
• Keep all components and the trace heaters dry before and during installation.
• Beware of hot surfaces when using the heat gun.
• Keep these instructions for future reference. If applicable, leave them with the end user.
• De-energize before installation or servicing.
• Use only original accessories.
Preparation of the trace heater
WARNING:
Risk of re or electrical shock. De-energize all power circuits before installation or servicing. Always
use ground fault equipment within the heat tracing system.
• Double-check that all power circuits are de-energized before you begin your work.
• Make sure that you do not exceed the maximum heating circuit length for the trace heater type you
use. Refer to the system manual of the heating system.
WARNING:
Risk of electrical shock and material damage. The gland body and grommet for PX/RX trace heaters
are slightly dierent. Make sure to use the cable gland kit that ts the trace heater you use.
WARNING:
Risk of burns. Beware of hot surfaces when using the heat gun.
Installation Instruction
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8 Sécurité et avertissements
An de garantir la sécurité lors de l’installation et de l’utilisation du système de connexion à liaison froide, il est
impératif de respecter les exigences ainsi que les consignes techniques mentionnées dans le présent manuel.
AVERTISSEMENT:
Risque d’incendie ou d’électrocution. Suivez ces consignes pour éviter toute blessure ou dommage
matériel.
• Tous les systèmes et installations électriques doivent satisfaire aux exigences imposées par la société
Danfoss et doivent être installés conformément aux normes électriques en vigueur ainsi qu’aux autres
prescriptions nationales et locales applicables.
• Les normes électriques américaines et canadiennes imposent une protection contre les défauts à la
terre pour tous les circuits de traçage électrique.
• La pose du système de connexion et des câbles chauants doit être réalisée avec le plus grand soin.
• Utilisez le câble chauant et le système de connexion adaptés à l’usage prévu et répondant aux carac-
téristiques de fonctionnement spéciées à la section Caractéristiques techniques.
• Le rayon de courbure du câble chauant ne doit pas être inférieur à 1”(25 mm). Ne pas courber le
câble chauant sur la tranche.
• Tout élément défectueux dans le kit doit être remplacé avant l’installation.
• Pour éviter un court-circuit, ne jamais raccorder ensemble les deux conducteurs du câble chauant.
• Conservez tous les éléments et les câbles chauants au sec avant et pendant l’installation.
• Soyez prudent lors de l’utilisation du pistolet à air chaud, certaines surfaces peuvent devenir brûlantes.
• Conservez ces instructions pour un usage ultérieur. Le cas échéant, remettez-les à l’utilisateur nal.
• Mettre hors tension avant toute installation ou opération de maintenance.
• Utilisez exclusivement des pièces et accessoires d’origine.
Préparation du câble chauant
AVERTISSEMENT:
Risque d’incendie ou d’électrocution. Mettre tous les circuits électriques hors tension avant toute instal-
lation ou opération de maintenance. Toujours utiliser un dispositif de protection contre les défauts à la
terre au sein du système de traçage électrique.
• Vériez bien que tous les circuits électriques sont hors tension avant de débuter votre travail.
• Veillez à ne pas dépasser la longueur de circuit de traçage maximale autorisée pour le
type de câble chauant utilisé. Consultez à ce sujet le guide de conception du système
de traçage.
AVERTISSEMENT:
Risque d’électrocution et/ou de dommages matériels. Le corps du presse-étoupe et le passe-l destinés
aux câbles chauants PX/RX sont légèrement diérents. Prenez donc garde à bien utiliser le corps du
presse-étoupe et le passe-l adaptés au câble chauant utilisé.
AVERTISSEMENT:
Risque de brûlure. Soyez prudent lors de l’utilisation du pistolet à air chaud, certaines surfaces peuvent
devenir brûlantes.
Vous pouvez trouver des instructions en Français ici: lx.danfoss.com
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Danfoss
11655 Crossroads Circle
Baltimore, MD 21220 USA
Phone: 1-888-DANFOSS (326-3677)
Fax: [phone]
lx.danfoss.com
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without
notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications
already agreed. All trademarks in this material are property of the respective companies. DEVI and the DEVI logo-type are trademarks of Danfoss A/S. All rights reserved.
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