Thermon Terminator ZP/FAK-1 Reference guide

Terminator ZP/FAK-1
For Bulkhead Entry of
Electrically Heated
TubeTrace® Bundles
INSTALLATION PROCEDURES

2
Terminator ZP/FAK-1
The following installaon procedures are suggested guidelines
for the installaon of the Terminator ZP/FAK-1 Bulkhead Entry Kit.
Receiving, Storing and Handling
1. Inspect materials for damage incurred during shipping.
2. Report damages to the carrier for selement.
3. Idenfy parts against the packing list to ensure the proper
type and quanty has been received.
4. Store in a dry locaon.
Provided by others — 8 each 8-32 stainless steel bolts, washers
and nuts required.
Tools Required
PETK Power and End Terminaon Kits (per heater)
PETK-1D for BSX, RSX, VSX-HT
PETK-2D for KSX, HTSX
PETK-3D for FP, HPT
Required: Order Separately for each heater to be fabricated
A
mm (inch)
B
mm (inch)
C
mm (inch)
D
inch (mm)
Terminator ZP/
FAK-1
220 mm
(8-5/8”)
277 mm
(11-7/8”)
107 mm
(4-1/4”)
171 mm
(6-3/4”)
D
B
A
C
8
7
Terminator ZP/FAK-1 Kit Contents
Item Quanty Descripon
1 1
Expediter Assembly: Flat Mount Base, Grommet,
Threaded Grommet Compressor, and Support Cap
with O-Ring
21 Juncon Box Lid
31 Juncon Box Base with O-Ring
41Nut
5 1 Terminal Blocks with DIN Rail (Refer to terminal
specicaons for maximum allowable wire size)
6 1 Juncon Box Cord
71 FAK-1 Cover (Top)
8 1 FAK-1 Cover (Boom)
91 Heat Reecve Tape
10 2RTV Sealant Tube
11 1 Glass Fiber Tape
12 1 Silicone Gasket
13 1 Self-Vulcanizing Tape
12 4
36
5
910
11 12
13
Dimensions

3
The Terminator ZP/FAK-1 Split Bulkhead Entry Kit is designed to
make a waterproof seal over the end of TubeTrace and terminate
Thermon electric heat trace in an approved juncon box. Review
Instrucons prior to installaon. Kit will make one connecon.
INSTALLATION PROCEDURES
Installaon Precauons
• To minimize the potenal for arcing on electrical heat tracing
and re caused by product damage or improper installaon,
use ground-fault protecon.
• Installaon must comply with Thermon requirements and be
installed in accordance with any applicable naonal and local
codes.
• Component approvals and performance rangs are based on
the use of Thermon specied parts only. User supplied power
connecon ngs must be listed or cered for intended use.
• De-energize all power sources before opening enclosure.
• Keep ends of bundles, heat tracing and kit components dry
before and during installaon.
• Individuals installing these products are responsible for
complying with all applicable safety and health guidelines.
Proper personal protecve equipment, or PPE, should be
ulized during installaon. Contact Thermon if you have any
addional quesons.
Terminator ZP Cercaons/Approvals
2. Trim heat tracing to within 305 mm–381 mm
(12”–15”) of the end of the insulation. If
self regulating heat trace proceed to step
3. For Zone-type heat trace continue with
indencaon of bus connecon on step 2a.
1. Remove outer jacket and insulaon from tubing
bundle as included from end of the tubing
bundle. Ensure sucient heat trace is available
for electrical connection. See instructions
included with heat trace PETK kit (purchased
separately).
2a. Strip back bundle insulaon 38 mm (1-1/2”)
to 76 mm (3”) beyond bus connecon heat
tracing. If bus connecon indentaon is less
than 305 mm–381 mm (12”–15”) from end of
the heat tracing, proceed stripping the bundle
insulaon to the next indentaon.
3. Wrap tubes and heat tracing with pass of heat
reecve tape (25% overlap). Then wrap with 3
passes of glass ber tape (50% overlap), or unl
ber tape is equal to original bundle insulaon
thickness.
4. Complete with additional passes of heat
reecve tape.
Trim as Required
for Connecon
Tubing Bundle
Tubing
Heat Tracing
Tubing
Self-Regulang Heat Tracing
Heat Tracing
305 mm–381 mm
(12”–15”)
Insulaon
Zone Type Heat Tracing
Tubing
Bus Connecon
Indentaons
(Zone Heater Only)
305 mm–381 mm
(12”–15”)
Insulaon
Glass Fiber Tape
Heat Reecve Tape
Heat Tracing
5. Cut FAK-1 top and base ends to match outside
diameter of tubing bundle and remove end
pieces.
Heat Reecve Tape
Glass Fiber Tape
Heat Tracing
Tubing
CAUTION (Found on TubeTrace SE/ME bundles)
Do not cut or damage the heat
trace or sampling tube.
Tubing Bundle
Cut and Remove
to t
Heat Tracing
Field Drilled
(By Others)
IP66/Type 4X -60°C ≤ Ta ≤ +55°C
Listed Heat Tracing Cable System 137M
Ordinary & Hazardous Locaons
Class I, Division 2, Groups A, B, C, & D
Class II, Division 2, Groups F & G, Class III
Class I, Zone 1, AEx eb IIC T4-T6
09.2238691,-G,-S, Ex e IIC T4-T6
FMG 10.0022X Ex eb IIC T4-T6, Ex tb IIIC T135°C-T85°C
1725 II 2 GD Ex eb IIC T4-T6, Ex tb IIIC T135°C-T85°C FM 10ATEX0058X

4
Terminator ZP/FAK-1
6. Mount expediter base with o-ring to FAK-1
base using (3) M5 mounng screws and lock
washers. Punch out weep hole.
O-Ring
Expediter
Base
Mount Screw
and Washers
Weep Hole
FAK-1 Base
Silicone
Gasket
7. Install RTV silicone and gasket, cung o excess.
Apply RTV sealant to both halves.
Drilled hole
for bundle
entry
Drilled holes
for securing
FAK-1
Drilled holes for
securing FAK-1 Use as template
11. Field drill required entry hole in wall/plate. Use
the FAK-1 ange as a template and mark and
drill holes for bolts.
9. Apply self-vulcanizing tape around bundle jacket
and work up over FAK ends.
FAK-1
Boom Cover
FAK-1
Top Cover
RTV Sealant
12. Apply RTV bead to back of FAK-1 ange prior
to securing to bulkhead.
RTV Bead
Backside View
Stainless Steel Bolts
14. Apply RTV bead around FAK-1 ange. 13. Secure FAK-1 to bulkhead/wall using (8) eight
stainless steel bolts. Note: stainless steel
bolts, washers, and nuts provided by others.
Recommended bolt size is 8-32.
8. Assemble FAK-1 top, tubing bundle, and FAK-1
boom together as shown Snap together rmly.
Inspect ends of tubing splice cover for snug t.
Apply addional RTV sealant where needed.
10. Terminate heat tracing with appropriate PETK
termination kit. Refer to PETK installation
instrucons (purchase separately) for details
not addressed here.
Power Connecon
Boot
Heat Tracing
Ground Braid

Thermon • 100 Thermon Dr • PO Box 609 San Marcos, TX 78667-0609 • Phone: [phone] • 1-800-820-4328
For the Thermon oce nearest you visit us at . . . www.thermon.com
© Thermon, Inc. • Printed in U.S.A. • Informaon subject to change.
Typical Wiring Diagram.
L 2 or N
L 1
Power Supply
Ground
Power Cable
Heat Trace
Ground Braid
Form 50079-0219
INSTALLATION PROCEDURES
15. For power connection applications: Use
dimple molded into side of juncon box base
to locate center hole, drill for user supplied
power connecon ng per manufacturer’s
recommendaons.
16. Mount juncon box on expediter making sure
to align slots to properly orient juncon box
base.
Align Slots
Dimple for
Center Line Drilled thru (1) Wall
21. Completed Terminator ZP/FAK-1 for bulkhead
entry of electrically heated TubeTrace bundles.
Power
Connecon
Bulkhead
17. Install quick mount terminal blocks twist to
position and tighten screws. (By others for
power connecon applicaon.)
Terminal Blocks
(Typical)
18. Complete system wiring between fabricated
heat tracing and power supply wiring. See
wiring diagram.
Power Wiring &
Conduit By Others
19. Install juncon box lid and twist hand ght.
Insert screwdriver into ratchet slot located
on side of juncon box base to ghten. Use
screwdriver ratchet on juncon box lid. Lid will
rotate 30°.
30°
20. Lid latch mechanism fully engaged. To remove
lid, repeat step 15 but in opposite direcon.
Conduit and Wire (By Others
For Power Connecon Applicaons)