Nelson PLT-BC User manual

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
DESCRIPTION
The PLT-BC Standard Power Connection Kit is for use with all
versions of Nelson Heat Tracing Systems’ LT, CLT, HLT and
NC heater cables. Compatible for use with any vendor’s heater
cables smaller than 11mm (0.44”) diameter.
KIT CONTENTS
1 Junction Box 1 Power Termination
1 Label 1 Box Adapter
1 Terminal Block 1 Gasket
1 Conduit Locknut 1 Tube of Silicone
1 Sealing Grommet 1 End Seal
1 Stand-off 2 Pipe Clamps
1 Uninsulated Splice Connector
Power Termination
Terminal Block
Junction Box
*Heater Cable
Conduit Locknut
Gasket
Box Adapter
**Sealing Grommet
Pipe Clamps
*Heater Cable
(see warnings below)
End Seal
*Conduit & Drain
*Ground Locknut
*Flex
Conduit
*ITEMS NOT INCLUDED IN KIT
Stand-off
J-Grommet - Overjacket Products
B-Grommet - Base Products
U-Grommet - Double Entry or non-standard construction
**Sealing Grommets
(For dual connections 1 additional power termination
and end seal will be included in kit.)
Silicone
Box Cover Gasket
Box Cover
Label
Note: This detail shows Braided “CB” Product only. For Overjacket “J” or “JT” Products, see
diagram on sheet 8.
!
WARNINGS:
•Article 427 of the National Electric Code requires that all heaters shall have metal coverings and
be provided with branch circuit ground-fault protection.
•If nuisance tripping of ground fault breakers occurs due to condensation in the junction box,
electrical connections should be moisture proofed by use of a coating or sealant.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 1 of 8
October 2006

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
STAND-OFF POSITIONING
8 o'clock 4 o'clock
Section View A A
(recommend installing at the
4 or 8 o'clock positions.)
!
Do not place pipe clamps
over the heater cable.
WARNING:
Stand-off
Fiberglass Tape
Sealing Grommet
Pipe Clamps
Box Adapter
not included in kit
Fiberglass Tape
254mm (10") A
A
Stand-off
not included in kit
Mark pipe where stand-off will be mounted. See drawing above.
Push heater cable through bottom opening of stand-off.
Place stand-off on pipe and fasten with pipe clamps included.
Slide the sealing grommet over the heater cable and position inside stand-off opening:
For Braided “CB” Products only:
See “Sealing Grommet Installation for Braided “CB” Products” on sheet 3.
Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.
Slide the box adapter over the heater cable and tighten securely to stand-off.
Prepare heater cable for power termination:
for Braided “CB” Products, see sheet 3.
for Overjacket “J” or “JT” Products, see sheet 4.
Terminate heater cable, see sheet 7.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 2 of 8
October 2006

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
SEALING GROMMET INSTALLATION FOR BRAIDED “CB” PRODUCTS
13mm (.5")
Slide braid back over heater cable and twist excess
braid into a pigtail.
Slide braid back, allowing at least 13mm (.5”) of
heater cable exposed.
Slide the sealing grommet over the heater cable and
position inside stand-off opening.
Cut and remove the exposed heater cable.
Continue with step 5 on sheet 2.
BRAIDED “CB” PRODUCTS
127mm (.5")
Bend heater cable and work it through the braid
opening.
114mm (4.5")
Secure heater cable braid with fiberglass tape,
allowing 127mm (5”) of cable for stripping.
Slide braid back towards the fiberglass tape creating
a bulge.
At the bulge, separate the braid to make an opening.
Pull the braid tight.
Proceed to “LT, CLT & HLT Products” on sheet 5.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 3 of 8
October 2006

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
OVERJACKET PRODUCTS
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 4 of 8
October 2006
127mm (5")
Lightly cut around heater overjacket 127mm (5")
from the end. Bend cable to break overjacket.
Lightly cut overjacket up the center between first
cut mark and the cable end. Bend cable to break
overjacket.
Remove overjacket from heater cable.
Move braid back toward the overjacket, creating
a bulge.
At the bulge, separate the braid to make an opening.
While bending the heater cable, work it through the
braid opening.
114mm (4.5")
Pull the braid tight.
Proceed to “LT, CLT & HLT Products” on sheet 5.
DO NOT CUT BRAID
WARNING:
!

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
FOR ALL NELSON LT, CLT & HLT PRODUCTS
(See sheet 6 for an alternate stripping method for HLT products.)
102mm (4")
Lightly cut around cable outer jacket 102mm (4")
from the end. Bend cable to break outer jacket.
Starting at the end, pull each bus wire away from
the core material.
Lightly cut the outer jacket up the center between
the first cut mark & the cable end. Bend cable to
break outer jacket.
Remove exposed core material.
Cut 6mm (0.25") off the end of each bus wire.
Proceed to “Power Termination” on sheet 7.
Remove the jacket from the heater cable.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 5 of 8
October 2006
!
DO NOT CUT BUS WIRES
WARNING:
Shave the core material from the outside of each
bus wire.

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
HLT PRODUCTS ALTERNATE STRIPPING METHOD
102mm (4")
Lightly cut around cable outer jacket 102mm (4")
from the end. Bend cable to break outer jacket.
Starting at the end, in the same plane as the cable,
pull each bus wire away from the core material.
Lightly cut the outer jacket up the center between
the first cut mark & the cable end. Bend cable to
break outer jacket.
Remove the exposed core material.
Remove the jacket from the heater cable.
Remove the remaining core material off the outside
of each bus wire.
Cut 6mm (0.25") off the end of each bus wire.
Make a cut inside each bus wire. Proceed to “Power Termination” on sheet 7.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 6 of 8
October 2006

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
POWER TERMINATION
!
WARNING:
•Bus wires must not touch or cross while
inserting into power termination. 13mm (.5")
•Only power terminations / end seals
specifically approved for the vendor’s style
and type of heater cable must be used.
apply silicone here
Push power termination to overlap jacket.
The silicone will set up in about 30 minutes with a
complete cure after 24 hours.
Proceed to “Power Connection” on sheet 8.
Insert bus wires into power termination.
Squeeze power termination opening and fill with
silicone.
END SEAL
apply silicone here
Fiberglass Tape
not included in kit
Squeeze end seal and fill with silicone.
Push end seal over the heater cable.
Overjacket “J” or “JT” Products only:
Braided “CB” Products only: The end seal should overlap the overjacket.
Cut braid back 25mm (1") & tape in place with
fiberglass tape.
The silicone will set up in about 30 minutes with a
complete cure after 24 hours.
Overjacket “J” or “JT” Products only:
Remove 13mm (0.5") of overjacket exposing the
braid, then remove the 13mm (0.5”) of exposed
braid.
!WARNING:
•Do not megger or hi-pot until silicone is
completely cured.
Make a 10mm (0.4") cut at the end of the heater
cable. •Braid must be kept away from bus wires
or shorting will occur.
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 7 of 8
October 2006

NELSON™HEAT TRACING SYSTEMS INSTALLATION
PLT-BC STANDARD POWER CONNECTION KIT INSTRUCTIONS
POWER CONNECTION
Ground Wire
Terminal Block
Ground Braid
Power Termination
TERMINAL BLOCK CONNECTION
Ground
Power Leads
Braid
Heater Cable
*Conduit & Drain; not included in kit
(must be positioned lower than the junction box)
Note: This detail shows Overjacket “J” or “JT” Products only. For Braided “CB” Product, see diagram
on sheet 1.
Place gasket on box adapter.
Position junction box on box adapter and secure it with the conduit locknut.
Connect bus wires, power wires and ground braid to the terminal block. See diagram above.
For Overjacket “J” or “JT” Products only:
Apply silicone at point braid leaves the overjacket
Push all wires, cable and terminal block inside junction box.
Place the box cover and box cover gasket onto the junction box.
Fill-in the voltage, catalog number & wattage blocks on the label with the actual field installed data.
Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at
P.O. BOX 726 TULSA, OK 74101 TEL [phone] FAX [phone] www.nelsonheaters.com
GA-1859 Rev. 6
Sheet 8 of 8
October 2006
www.nelsonheaters.com.