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Report t , ifrj�.0l�' T�` a I xitic 1E EJB Junction Boxes Cl. I, Div. 1 and 2, Groups B, C, D Ex d 118 + H 76, IP66 Cl. H, Div. 1, Groups E, F, G Explosionproof RECEIVED CI. II, Div. 2, Groups F, G Dust-Ignitionproof Cl. III Raintight MAY 18 2016 NEMA 3, 4, 4X', 7, 9 Wet Locations Applications: CI I Y Q1-TIGARD BUILDING DIVI I• ► . EJB junction boxes are used in threaded Tii,y p a a: rigid conduit systems in hazardous areas: i • As a junction or pull box - ' • To provide enclosures for splices and branch circuit taps " , • For housing terminal blocks,relays and i' y other electncal devices • Indoors or outdoors in damp,wet,dusty, corrosive,hazardous locations • Where exposure to frequent or heavy rain, EJB121208 with optional hinged cover EJB121208 with optional hinged cover water,spray,moisture,and humidity is and standard neoprene cover gasket common,such as:offshore drilling facilities, cooling towers,coal preparation and handling facilities and sewage and waste Certifications and Options: water treatment plant Compliances: Description Suffix • In areas which are hazardous due to the • Hinged covers presence of hydrogen or gases and vapors • NEC/CEC Hinges mounted on left of equivalent hazard such as found in Class I.Divisions 1 and 2,Groups B', (short side) S598 process industries,missile bases and gas Ct and D$ manufacturing plants Available on all Style C and the Class II,Division 1,Groups E,F and G following Style D enclosures: Features: Class II,Division 2,Groups F and G EJB101008-SA,EJB120804, • Style C boxes provided with aluminum Class III EJB120804-SA,EJB120808-SA, and EJB141006•SA plate cover as standard,allowing for field Class I,Zones 1 and 2 addition of cover device holes • UL Standard 1203 Hinge kits for field installation • Stainless steel cover bolts(Style C only) • cUL to CSA Standard C22.2 No.30 (no field machining required)- EJB KIT 1 • Ground joint cover opening provides • ATEX:Ex d 118 t Hz T6,IP66 • EJB100806 through 361208 (2 hinges) maximum opening for pulling wires or ATEX certificate:PTB 01 ATEX 1020 U EJB KIT 3 mounting equipment • Enclosure Type 3.3R,4,4X'.7BCD.9EFG • EJB361808 (3 hinges) • Walls of bodies may be drilled and tapped • IEC Standard EN.60079-0 and EN:60079-1 EJB KIT 4 for conduit entries as shown in listings • Stud bolts in diagonally opposite corners of • ForEJEJ 408 (4 hinges) L.0 Standard Materials: • For EJB101008-SA,EJB120804, body aid in aligning cover to body during • Body and cover-copper-free aluminum EJB120804-SA,EJB120808-SA EJB KIT 5 installation(not furnished with hinged covers) (suffix-SA items and all Style C),Feraloy' and EJB141006-SA (2 hinges) • All Style C bodies are provided with iron alloy(Style D) Factory installed mounting captive,triple lead,quick release hex head • Gasket-neoprene plates for relays,terminal stainless steel bolts with spring loaded • Cover bolts-stainless steel(Style C),steel blocks,electrical devices,etc.- action which provides clear indication (Style 0) • Aluminum mounting plate kit for that cover bolts are fully retracted from • Hinges-stainless steel field installation(kit includes the body aluminum mounting plate,pillars • External flange design-wide unobstructed Standard Finishes: and mounting hardware). No field machining required. cover opening provides a completely • Copper-free aluminum-natural accessible interior for wiring and electrical See Ordering Information on equipment • Peratoy iron alloy-electrogalvanized and next page MP • Square corners of enclosure body provide aluminum acrylic paint • Factory installed terminal Information • Steel-electrogalvanized blocksre t maximum interior space and area for request s conduit openings • Extruded aluminum-natural • ATEX Certified ATEX • Internal grounding lug provides a means to ground enclosed equipment Gasket Detail • Special neoprene cover gasket provides a watertight seal to meet NEMA 4 e‘z requirements,and provides superior MI protection for enclosed equipment against aWAH water/corrosion ,Il/ Ir 'M • IEC rated when ordered with ATEX suffix I I• Enclosures are machined for field installed o'►` mounting plates 05" , 1, • Detachable mounting feet provide mounting flexibility.No need to replace Cross section of cover. Bolted cover and body assembled. enclosure if mounting feet are broken. Gasket extends beyond flange Compressed gasket forms watertight • Optional stainless steel hinges provide surface by.05". seal. convenient and easy access for inspection. maintenance and systems changes 'rot Group8,install sealing kinin n each conduct run within 18'of the enclosure To meet 4X r • Enclosures are machined to accept field g g' requirement,add sued P S752 or S753 installed hinges tEJ8361208.361808.362408 and all style D enclosures require sealing fittings within 18 of enclosure for each conduit wn for Group C locations. /Style 0 enclosures require sealing fittings within 18'of enclosure for each conduit run fur Group D locdnoos. For conduit Imer ordering information.see page 860. Crouse-Hinds 730 www crouse-hinds corn US.1-866-764.5454 CAN 1-800-265-0502 Copynghr 2013 Eaton's Crouse-Hinds Business 5y IF:T•N EJB Junction Boxes Cl. I, Div. 1 and 2, Groups B, C D Ex d IIB + H T6, IP66 i E Cl. II, Div. 1, Groups E, F, G Explosionproof Cl. II, Div. 2, Groups F, G Dust-Ignitionproof CI. III Raintight NEMA 3, 4, 4X*, 7, 9 Wet Locations 6 r I ., ,„;!' Ordering information: Junction boxes listed can be furnished 1' "` with drilled and tapped openings, , subject to material required and the ;, (: limitations of maximum size and number _iii --' of openings as well as spacing,as shown r r 4 > in Tables 1 and 2. � : To Order: - ,t - Step 1 s" Select the box required from photos at i1 ` , left,listings,and dimensional drawings ;x..z on next pages. I - . ` - Step 2 Select standard conduit arrangement from Style D Style C-EJ6121208•with optional Table 1 and maximum size conduit hinged cover opening required from Table 2. Step 3 Nominal Inside Dimensions Select appropriate symbol for required Style Material Cat.I Sides(sal Top&Bottom(bb) Depth Mounting Plate drilled and tapped opening from Table 3. D Iron EJ6060404 4 6 4 MP0406 Example. D Iron EJ8080604 6 8 4 MP0608 Step 1 -Box required-EJ8080806 D Iron EJB080606 6 8 6 MP0608 Step 2-Arrangement-2 D Iron EJB080806 8 8 6 MP0808 Step 3-Openings-two 1•drilled and D Iron EJB120804 8 12 4 MP0812 tapped holes in top and bottom and two D Iron EJB160404 4 16 4 MP0416 2"drilled and tapped holes on each side. D Aluminum EJB060404 SA 4 6 4 MP0406 Step 4-Symbols are substituted and D Aluminum EJB080604 SA 6 8 4 MP0608 written in clockwise order starting with D Aluminum EJB080606 SA 6 8 6 MP0608 'a.' When no opening is required at a D Aluminum EJB080806 SA 8 8 6 MP0808 particular location,use symbol'0"(zero). D Aluminum EJB120604 SA 6 12 4 MP0612 For this example:CC,GG,CC,GG. D Aluminum EJB120804 SA 8 12 4 MP0812 Complete Cat.No.is made up of three f1: D Aluminum EJB120808 SA 8 12 8 MP0812 D Aluminum EJ8160404 SA 4 16 4 MP0416 parts:arrangement number;Part 1 -box number;Part 2- D Aluminum EJB101008 SA 10 10 8 MP1010 EJBopenings.080806-2-CC-GG-CC-GG For this example: Part 3-symbols for conduit D Aluminum EJB141006 SA 10 14 6 MP1014 C Aluminum EJ8100806 8 10 6 MP0810 If none of the standard arrangements C Aluminum EJB121204 12 12 4 MP1212 meet requirements,send a sketch C Aluminum EJ8121206 12 12 6 MP1212 showing junction box number with size C Aluminum EJB121208 12 12 8 MP1212 and location of each conduit opening C Aluminum EJ8161606 16 16 6 MP1616 desired. C Aluminum EJB161608 16 16 8 MP1616 C Aluminum EJ8181206 12 18 6 MP1218 C Aluminum EJB181208 12 18 8 MP1218 C Aluminum EJ6241208 12 24 8 MP1224 C Aluminum EJB241210 12 24 10 MP1224 C Aluminum EJB241808 18 24 8 MP1824 C Aluminum EJB241810 18 24 10 MP1824 C Aluminum EJ8242408 24 24 8 MP2424 C Aluminum EJ8242410 24 24 10 MP2424 C Aluminum EJ8361208 12 36 8 MP1236 C Aluminum EJ8361808 18 36 8 MP1838 C Aluminum EJB361810 18 36 10 MP1836 C Aluminum EJB362408 24 36 8 MP2436 C Aluminum EJB602212t 22 60 12 MP2260 l'Class I.Division t and 2.Groups C and D only. -See Compliances on previous page For conduit liner ordering informationsee page 860. Crouse-Hinds '1v FcY•N AW,.crouse-hinr]s corn US ;-860-754-5454 CAN 1-800-265-0502 Copyright' 2013 Eaton's Crosse-Hrntls Business 1" .. 1 1E EJB Junction Boxes Ordering Information Table 1 Conduit Arrangement Diagrams top (bilk. k a a b a b c a b c d side 1s L: La 13iii_4 __4a (aa) r aim d b 1 S a 9 d e ^ f-- � 11111 bottom c side 1 e I h g m l k j (bb) (ea) 1 2 3 4 a b c d e abcde t g Ls Ls Ls Ls T' LT T:, T vWit 1 D h ug abode f a a b c d e f g h s .jLe La Le Le L6 2 tim V.r.rr✓irrk z 9 z ti n H i y F' h P F 1- j X t• j ti m t- n q p n m l u '-1 w v u t s r q p t �' m � Is r g p n z yxwvu i s 5 6 7 8 Table 2 Conduit Arrangements-Style D Maximum Trade Size and Number of Openings Spacing Top and Bottom(bb)' Sides(aa) Dimensions Cat.# 1 2 3 4 1 2 3 4 S L S2 Lu S2 L. S. EJB060404 2 1'/. '1 - 2 '/: - - 2'4 1'/e 1'/•• 21/4 - - - EJB080604 2 2 1 '/: 2 1'h 'h - 21/4 2'/s 1'/e 21/4 2'/a 21e - EJB080606 31/2 2 1 'h 31/2 1'1. 'h - 3'/. 2'/. 1'/. 2'/. 2'!. 27.. - EJB080806 31/2 2 1 '/a 3'h 2 1 'h 33/. 21/2 2'/. 2'/. 2'h 2'/.. 2'h. EJB101008 4 2'4 11/2 1 4 2'12 1'/2 1 43/. 2'/. 2'/. 31/4 3'/. 21/4. 2'/.e EJB120604 2 2 2 1'/. 2 1'6 '6 - 2'/. 3 11/4 4'/. 2'/a 3'/. - EJB120804 2 2 2 1'!. 2 2 1 'h 2'/s 3 2'h 4'/a 21/4 31/2e 21/2. EJB120808 4 4 2 1'/. 4 2 1 'h 4'/. 3'/. 21/4 41/4 2! 31/2. 2'/.e EJB141006 3'h 3'h 2'h 1'6 31/2 21/2 1'h 1 31/4 31/4 21/4 5 3'hc 3'/. 21/4. EJB160404 2 2 2 2 2 'h - - 2'/e 3 1'/., 6 - 41/4 - -Top and bottom are longer denens.ons on enclosures which are not square. Conduit seals are required in all conduit entrances for Class I,Division 1.Group B hazardous areas,and tor EJB361208.EJB361808.EJ836181 D,EJ8362408,and all Style D enclosures when used in Class I,Division 1,Group C hazardous areas.For other sealing requirements.consult the National Electrical Code'.Where standard arrangements are not adequate,special drilling and tapping can be Ordered.or instructions can be provided for held drilling and tapping Breathers and drams must be ordered separately.Maximum trade size ter Group B application.s 4'. Crouse-Hinds 732 wWV:C 3uSn h<ds Com LIS -Bob 545-1 r�AN 1-P,00-255-05-.^2 Coot' qr, 2013Exon*,-;C „,..e-r1'Cs 8.:5 naS; by W 1•M • PENTAIR RECEIVED MAY 18 2016 Raychem HAK- C - 10 0ARD BUILDING F DIVISION CONNECTION KIT FOR IIVISION 1 HAZARDOUS LOCATIO\IS INSTALLATION II\STRUCTI-NS DESCRIPTION The HAK-C-100 is a connection kit designed for use in Division 1 hazardous locations with the Raychem industrial heating cables listed on page 2 of these instructions.The kit contains materials for sealing one heating cable entry when making a power,splice,tee,or end termination.A heat- shrinkable core seal is provided specifically for use with LBTV2-CT heating -,;-{ f", cables.For all other heating cables,a CS-100 cold-applied core seal is > .1x t provided. Refer to the Heat-Tracing Systems Design and Installation Guide for -\� Hazardous Div.1 Locations(H56075)for assistance in the design of A each heat-trace system.For technical support call Pentair Thermal --- -) Management at(800)545-6258. TOOLS REQUIRED � • 1/2 in drive ratchet • Marking pen • Diagonal cutters • Utility knife • Needle nose pliers • 5/16 in hex key • 3/16 in slotted screwdriver • Ruler • 1/4 in hex key • Pipe wrenches(2 required) • 1/16 in hex key • Wire strippers(for VPL only) APPROVALS • 2500 Vdc Insulation Resistance Tester • Heat gun or minitorch(required if heat-shrinkable core seal is used) Hazardous Locations ill ADDITIONAL MATERIALS REQUIRED Class I,Div.1,Groups B,C,D • Junction box:Raychem HAK-JB3-100 or agency-approved Division 1 Class II,Div.1,Groups E,F,G hazardous location 3/4 in NPT junction box.Junction boxes other than SPclass III the HAK-JB3-100 may not be compatible with the Raychem universal �! mounting bracket. ill Except VPL. • Small volume of water • Universal mounting bracket(UMB)—one per junction box KIT CONTENTS • Pipe strap—one per mounting bracket Item Qty Description A 1 HAK sub-assembly:seating fitting,nipple,and plugs B 1 Union N C 1 Packing fiber A � ® M D 1 Sealing compound E 1 Tubing clamp B ,...\•,\'‘ ii;°iN ' 4 :007'"%F 1 Compression gland with screws �� -' K G 1 Compression gland with threaded inserts C AL `r� ' 1111 3 H 5 Grommets(B,C,E,K,R) O 1� I 1 Flex tube D �p, J 1 Terminal block(max:b AWG wire) E — �,� WI ,-X1P �®®®® H K 2 Black heat shrinkable tubes L 1 Clear yellow heat-shrinkable tube F -T Q M 1 Green/yellow tube N 1 CS-100 core sealer 0 WARNING: Q CAUTION: This component is an electrical device that must be installed correctly to • Keep components and heating cable ends dry before and during installation. HEALTH HAZARD:Prolonged or repeated contact with the sealant in the core ensure proper operation and to prevent shock or fire.Read these important • The black heating cable core and fibers are conductive and can short. sealer may cause eye or skin irritation.Wash hands thoroughly.Overheating warnings and carefully follow all of the installation instructions. They must be properly insulated and kept dry. or burning the sealant will produce fumes that may cause polymer fume fever. • To minimize the danger of fire from sustained electrical arcing if the • Damaged bus wires can overheat or short.Do not break bus wire strands Avoid contamination of cigarettes or tobacco.Consult MSDS VEN 0033 for heating cable is damaged or improperly installed,and to comply with when scoring the jacket or core. further information. Pentair Thermal Management requirements,agency certifications,and • Use only fire-resistant insulation materials,such as fiberglass wrap or Overheating heat-shrinkable tubes will produce fumes that may cause national electrical codes,ground-fault equipment protection must be flame-retardant foam. irritation.Use adequate ventilation and avoid charring or burning.Consult used.Arcing may not be stopped by conventional circuit breakers. • Heat-damaged components can short.Use a heat gun or a torch with a MSDS RAY3122 for further information. • Component approvals and performance are based on the use of Pentair soft,yellow,low-heat flame.Keep the flame moving to avoid overheating, CHEMTREC 24-hour emergency telephone:18001424-9300 Thermal Management-specified parts only.Do not substitute parts or use blistering,or charring the heat-shrinkable tubes.Avoid heating other Non-emergency health and safety information:(8001545-6258. vinyl electrical tape. components.Replace any damaged parts. THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC 100-IM-H565'/3 01/13 1 /16 General Instructions Grommet Selection • The HAK-C-100 connection kit is for use only Heating Cable Heating Cable Heating Cable with the following heating cables: BTV,HBTV, for FM Only Grommet for FM Only Grommet for FM Only Grommet QTVR,HQTV,XTV, HXTV, LBTV2, FHP and VPL 5HBTV I-CT B 15HXTV1-CT R 200TVR1-CT E (-CT versions).Do not use this kit with any other 5HBTV2-CT B 15HXTV2-CT R 200TVR2-CT E heating cables. BHBTV-1-CT E 20HXTV1-CT R AIlXTV1-CT-T3 R • Select correct grommet from table on right. 8HBTV-2-CT E 20HXTV2-CT R All XTV2-CT-T3 R The grommet I.D.letter is embossed on each 10HBTV1-CT E FHP-2 E All XTV1-CT-T2 R grommet. 1OHBTV2-CT E FHP-3 C AIlXTV2-CT-T2 R 12HOTV1-CT C 5BTV1-CT B All VPL1-CT R 12HOTV2-CT C 5BTV2-CT B All VPL2-CT R ,� , 3 20HOTV1-CT E BBTV-I-CT E LBTV2-CT K fi '' �-aF ' 20HQTV2-CT E 8BTV-2-CT E ?_ �-r x 7?ii — �* " as .,k 5HXTV1—CT R 1OBTV1—CT E A s� , _ § i y �T , 5HXTV2-CT R 10BTV2-CT E �� l' a 10HXTV1-CT R 100TVR1-CT C = 0 ,,77 10HXTV2-CT R 100TVR2-CT C W S* I l 2 • Fasten the Raychem universal mounting bracket(UMB) • Thread compression gland with threaded inserts into or suitable mounting plate for another junction box to fitting until tight. the pipe at the desired location.Be sure the pipe strap is • Thread nipple into female half of union until tight. under the heating cable. • Thread nipple into sealing fitting until tight. * , * Nli C-4°Ptfr % Inserts 3 4 • Mount box on bracket. • Measure flex tube and cut to length from gland to pipe. • Thread male half of union into box entry. • Assemble union halves together. - tQ ) L7' kmiot , , .4(14110..!.19 Y ) >� a VI � -")Ifri •-_-,--: / ' s"-,---7'- Cut THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC100-IM-HC6573 01/13 2/16 5 • Select correct grommet from Important table on page 2. For VPL-CT only: Locate indentation • Slide parts onto heating cable (bus wire connection) as shown. at this point ,-1 • Slide heating cable through C `�,/ 16 in. fittings and box. �� / (41 cm) � • Repeat steps 2 through 5 for min. 0 each additional heating cable. ,�! u 6A For BTV-CT,HBTV-CT,QTVR-CT,HQTV-CT,FHP,XTV-CT,HXTV-CT,and LBTV2-CT heating cables Do Not x111 Cut Braid = 44%11 14 1/2 in. (37 cm) • Lightly score outer jacket as shown. • Bend heating cable to break jacket at score,then peel off jacket. Go to step 7. 6B For VPL-CT heating cables Do Not ' Cut Braid Indentation — (bus wire connection) 0 �1� I131/2 mmin.) 15 in. (38 cm) Aar. (38 1/2 in. v41/4. (37 cm) • Cut heating cable 15 in.(38 cm)from the indentation(bus wire connection). • Lightly score outer jacket as shown. • Bend heating cable to break jacket at score,then peel off jacket. Go to step 7. THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC100-IM-HDoo73 01/13 3/16 • D N 0 For VPL-CT only )� )# . Olk d--17-:. 1 ifill ‘ 4 ..kie 6 1/2 in. (165 mml • Push braid back to create a pucker. • At pucker use a screwdriver to open braid • Lightly score inner jacket around and down as shown. • Bend heating cable and work it through opening in braid. • Bend heating cable to break jacket at score,then peel off • For VPL-CT only:Cut and remove thread. jacket. 9A For XV-CT and HXTV-CT heating cables tiii I Nio11,,, 04* \ '.•.t. 11.10, 71-:4I <=7 • Cut and remove all fiber strands. ' ' • Score and remove center spacer. • Remove any remaining core material. Go to Step 10. 9B For BTV-CT,HBTV-CT,QTVR-CT,HQTV-CT,FHP and LBTV2-CT heating cables ,Il <21 1/4 in. ,'1:k4.\N ie '(b mml � % � �• : /II • Notch core. A• Peel bus wire from core. eVtgV" <:1 • Score between bus wires at inner jacket. • Remove any remaining core material. • Bend and snap core. For LBTV2-CT go to Step A on page 11. • Peel core from bus wire. For all other heating cables go to step 10. THERMAL MANAGEMENT SOLUTIONS 1 EN Ray,hemHAKC100-I M-H36373 01I13 4/16 9C For VPL-CT heating cables 4111111/4„../01 m) ►• 6t , li,, (16, 50•00: 00. 1/2 s ,, IP • Unwind heating element,cut and remove as shown. • Lightly score clear jacket around and down as shown. • Bend heating cable to break jacket at the score then peel off jacket. 3/8 in. • Remove 3/8 in. (9 mm) insulation from bus wires. (9 mm) 10 11 For VPL-CY only • Mark both sides of jacket 5/8 in.(15 mm)as shown.For • Cut off and discard end of core sealer legs. VPL-CT go to Step 11.For all other heating cables go to Step 12. _ 1111 1 2 in. ��ii�/��i//// 5 8 in. , \1(38/mm) //��///��/ (15 m m) ,///:://///, %�,, 12 13 • Refer to material safety data sheet RAY5510. • Push core sealer onto the heating cable to the mark made • If needed,retwist and straighten bus wires. in Step 10. • Insert bus wires into guide tubes as shown. Note: Extra force may be required for larger cables. • Make sure all strands go into tubes. ��`" Tubes lkii4 ,,,,, ,s 4 1 44 a'' THERMAL MANAGEMENT SOLUTIONS I EN-RaychernHAKC 100-IM-H56573 01/13 5/16 Ell m • Remove the tubes and dispose of them in a plastic bag. • Trim bus wires(except VPL-CT). • Trim braid. • Slip the green/yellow tube onto the braid. at 3/8 .1 3/8 in. (9 mm) "`'' alk 14 1/2 in. ,,i,,��,,, � ,,,,,ii'i6 (37 cm) 16A Heating Cable Test 1 Following the test method outlined below,perform an insulation resistance test on the heating cable using a 2500 Vdc tester. Test Method ,A ; • Perform Tests A and B at 500, 1000,and 2500 Vdc. • ,� Y r ': • Insulation resistance criteria is defined in Step 16b(page 7). • If the readings vary with the voltage refer to the { Troubleshooting Guide(page 12). :1,:i,::.:1;;‘,_-,:s,',-:_re--e:-s, ,- ' r ;'Test A — — — �� ` _ .,;`IR'Afi . *`• Connect the test leads as shown. e+ „• Measure the insulation resistance between the heating cable -a�� . bus wires and the undid. • Record the Test A insulation resistance values in the I X11-Heating Cable Test 1"section of the FM Required Division 1 Installation Record on page 14. \rTest B• Connect the test leads as shown. • Measure the insulation resistance between the braid and thetA — — — metal pipe. Test BIMPORTANT: - Be sure to isolate the braid from the ground before /��performing Test B. i( L�� ' - To perform Test B after sealing compound is poured into �;1sealing fitting(as braid may contact sealing fitting or junction -NNI —moibox),see illustration in Post-Thermal-Insulation Heating Cable Test 2,Step 21, page 8. T ®/• Record the Test B insulation resistance values in the �1• '"Heating Cable Test 1"section of the FM Required Division 1 ,'Installation Record on page 14. ,ii u u I u THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKCi00-IM-856373 01/13 6/16 • 16B Insulation Resistance Criteria A clean,dry, properly installed circuit should measure thousands of megohms, regardless of heating cable length or measuring voltage(0 to 2500 Vdc).The following criteria are provided to assist in determining acceptability of an installation where optimum conditions may not apply: • All insulation resistance values should be greater than or equal to 1000 megohms. • Insulation resistance values from Test A,for any particular circuit,should not vary more than 25%as a function of measuring voltage. • Insulation resistance values from Test B,for any particular circuit,should not vary more than 25%as a function of measuring voltage. If any of the above conditions is not met,consult the Troubleshooting Guide(page 12). 17 • Carefully pull heating cable back through box,making sure core sealer remains positioned at 5/8 in.(15 mm) mark.Continue pulling until end of outer jacket is centered in sealing fitting opening(see Step 18). c op> 4 18 19 • Be sure green/yellow tubing does not extend into sealing • Position grommet in gland cavity. fitting. • Tighten compression gland screws,being careful not to • Center heating cable as shown. change position of heating cable in sealing fitting (see Step 18). • Install flex tubing onto compression gland. • Tighten tubing clamp. II �a ® II'I�III �>> Ut .1 / 41i / Center i" THERMAL MANAGEMENT SOLUTIONS I EN-RavchenHAKC100-IM-FI56573 OI/13 7/16 20 • Loop and tape extra heating cable to pipe. • Apply insulation and cladding. l ores k) ��Pct° (........._j I, 1 - te --IA V" -_,40111,Sc,_2 1, \1� r ,..__, -) 1 l✓ 21 Post-Thermal-Insulation Heating Cable Test 2 Following the test method outlined below,perform an insulation resistance test on the heating cable using a 2500 Vdc tester. • Disconnect union and carefully pull braid out of junction box.Do not pull heating cable and CS-100 core sealer out of junction box. • Isolate sealing fitting and braid wire from junction box and pipe. INTest Method • Perform Tests A and B at 500, 1000,and 2500 Vdc. � • Insulation resistance criteria is defined in Step 16b(page 7). • If the readings vary with the voltage refer to the ' Troubleshooting Guide(page 12). i i Test A —•—•— t, , r r �,,a x a.. � �_�� • Connect the test leads as shown. • Measure the insulation resistance between the heating cable Test A —•—•— 1 - bus wires and the braid. i I • Record the Test A insulation resistance values in the"Post- Test B Thermal-Insulation Heating Cable Test 2"section of the FM /`" ,i' Required Division 1 Installation Record on page 14. Test B Isolate braid wire and ..... • Connect the test leads as shown. sealing fitting from C • junction box and pipe. Measure the insulation resistance between the braid and the 4 �-�W metal pipe. �,�` • Record the Test B insulation resistance values in the"Post- � -:„;,t1-,�� Thermal-Insulation Heating Cable Test 2"section of the FM �_ �, � Required Division 1 Installation Record on page 14. 7 •,/ 1 in. �� • Reinstall assembly in the junction box;be sure core sealer is .� (25 mm) fully installed over the end of the heating cable. IMPORTANT: 0'1.1% V Make heating 10remains ullng the ble braid wire out through the hub of the junction box. THERMAL MANAGEMENT SOLUTIONS 1 EN-RayThernHAKC I00-IM-1156573 01/13 8/ 16 • 22 • Refer to material safety data sheet VEN0025. • Pack fiber around heating cable as shown.Be careful not to damage cable. Mil itirit le 1111 FIi•'1 Now Packing fiber 23 15 IMPORTANT:To ensure that the sealing compound sets properly,maintain a minimum ambient temperature of iii 32°F(0°C)for 8 hours after pouring into fitting. A)Ai"/ 1 .* Ill-,,, ... .."------> is 0 • Refer to material safety data sheet VEN0024. \�'" • Weather-seal the bracket and flexible tube entries. • Mix sealing compound according to manufacturer's ....,_-.z-;-,„, arepour pourable paste. Pour ion on into seatainer.linglf Sealing mixture xture should be u Weather seal • Install plugs. 24 Green screw and washer • Discard small loose screw packaged with a grounding bar. Use larger green screw and washer supplied with HAK-JB3-100 junction box. J „G G,c.so E> (0k,, AK millill\ *< V° ),. W lbx2 ilo "el __,_. e 10-40,4>lk 'N ....,.___-_,, WO • Co nett braid to grounding bar. , • Connect ro nding bar to junction box. THERMAL MANAGEMENT SOLUTIONS 1 EN-RaychernHAKC 100-IM-E156573 01/13 9/16 25 For power connections only: • Install conduit and sealing fitting with drain. • Pull in power and ground wires. 26 Power Connection Splice Leads from power ® ® " Heating ' e 0 " Heating distribution panel r �Bo®" cable .B®.-- cable Ground wires y i Braid Braid i 1 i Braid �f Heating End Seal Tee � cable Make sure conductors __ are not exposed. Heating A 0 Heating 6 0 Heating cable ,�—a a cable ,�e°ej�,, cable Braid Braid /Braid • Make connections to terminal block For power connections only: [terminal block is installed "floating" Use agency-approved Class I, U Division 1 sealing fitting with in the junction box). drain valve(not supplied .n by Raychem). QM 18 in. `,� (45 cm) u I I I in I I I a ;._.__---,-,-;_, 4 • Inspect each core seal for proper placement. t!'j 400 • Stow wires in box. (...e:r. , �v'�G• Install cover and gasket. ��t �t '� ,,ng 0- ksI c'„ so • Tighten cover set screw. u u, THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC100-IM-H56Y,3 0I/13 10/16 Heat-Shrinkable Core Sealer Installation Instructions Use the heat-shrinkable core sealer with LBTV2-CT in place of the cold-applied core sealer shown in Step 12 on page 5. A B /\ WARNS *, ..: - '.:' --,''‘'' —aor n� 1/2 in. 40-:ttatitatis E�Or (13 mm) r a K r� -s ..? e • • ' 1f g Clear yellow tube POI .1• Black tubes / • Center clear yellow tube over end of inner jacket. • Refer to material safety data sheet RAY3122. • Heat tube until it shrinks and adhesive flows out ends. • Slide on black heat-shrinkable tubes. While still hot,immediately pinch between bus wires and • Use heat gun or minitorch with soft yellow flame to gently hold for 5 seconds to create a seal. heat tubes until they shrink. • Go to step 15 and continue with installation. THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC100-IM-H56573 01/13 11 /16 Troubleshooting Guide Symptoms Probable Causes Correction Insulation resistance is less than expected or Nicks or cuts in heating cable with or with- Check all connections in power,splice,tee, varies with voltage(500,1000,2500 Vdcj. out moisture present. and end seal kits for cuts in heating cable jackets,or for improper stripping distances. Short between braid and heating cable core Res heating.cable to remove damaged or between braid and pipe. areas or establsh proper distances.If heating cable is not yet insulated,visually inspect for Crossed bus wires in core seal. damage,especially at elbows and flanges and around valves.If system is insulated,discon- nect heating cable section between power kits,splices,etc.,and test again to isolate damaged section of cable.Use Raychem DET 2200 fault locator or other appropriate device to locate fault.Replace damaged heating cable sections. Meter needle oscillates rapidly or indicates Arcing created by damage to insulation or Same as above. charging and discharging. exposed electrical parts. Insulation resistance increases slowly with time. Moisture present between energized parts. Check all connections in power,splice,tee,and end seal kits for signs of moisture.Dry out con nections and retest.Be sure all conduit entries are sealed,and that condensate in conduit can not enter power connection boxes.If no water is present in connections,isolate sections - as described in correction outlined above.If heating cable.core or bus wires are exposed to large quantites of water,replace heating cable. Drying the heating cable is not sufficient,as the power output of the heating cable may be significantly reduced. Insulation resistance decreases rapidly during or Heavily wetted surfaces between energized Same as above. after the charging period. parts. Circuit breaker(GFPD(trips. Nick or cut in heating cable or power feed Replace damaged cable. wire with moisture present. Circuit breaker undersized. Resize the circuit breaker and wiring if ap plicable. Circuit oversized. Same as above. Startup at too low a temperature. Same as above. Defective circuit breaker. Replace circuit breaker. g Connections shorting out. To locate shorting problems,follow these steps: �. •Visually inspect the power connections,splices, ,n tees,and end seals for proper installation; ,,.:,,,i,,,,:3-,• - correct as necessary. •Check for visual indications of damage around the valves,pump,and any area where there may have been maintenance work. a ,x •Look for crushed or damaged insulation lagging along the pipe.Replace damaged sec- t tions of heating cable.Using a megohmmeter, ax -- � . do-} ',,1 ^N T+"" k test per installation instructions. tz�� ' �'�"�k'',.:,;;.,„.,„,..e:::-,.;,t-" ` � Physical damage to heating cable causing a Same as above. s m � direct short. . Bus wires connected at the end. Check end seal unction box to ensure bus t wires are secured properly in terminal block. � .: « The heating cable may have been permanently damaged by excessive current and may need to be replaced. Excessive moisture in connection boxes or Dry out and reseal connections and splices. splices. Using a megohmmeter,test per installation instructions. THERMAL MANAGEMENT SOLUTIONS I EN-RaychemHAKC 100-IM-H56573 01/13 12/16 Troubleshooting Guide Symptoms Probable Causes Correction Power output appears correct but pipe tempera- Insulation is wet. Remove and replace it with dry insulation,and tures are below design value. secure proper weatherproofing. 1 Insufficient heating cable was used on Splice in additional heating cable but do not go valves,supports,and other heat sinks. over maximum circuit length. Thermostat was set incorrectly. Reset thermostat. Improper thermal design. Check with the local or factory representa- tive for design conditions;modify as recom- mended. Power output is zero or appears low. Low or no input voltage. Repair electrical supply lines and equipment. Circuit is shorter than the design shows, Check routing and length of heating cable(use due to splices or tees not being connected, "as builts").Connect splices or tees,locate and or the heating cable having been severed. replace the damaged heating cables,then recheck the power. Improper connection causing a high-resis- Recrimp with the correct procedure.Tighten tance connection. set screws on terminal block. Control thermostat is wired in normally Rewire in the normally closed position. open position. Pipe is at an elevated temperature. Reduce pipe temperature.Check the pipe temperature.Verify the power output of heating cable.See note below for method. Heating cable has been exposed to exces- Replace damaged heating cable.Check the pipe sive moisture or chemicals. temperature.Verify the pov.ar output of heating cable.See note below for method. Heating cable has been exposed to exces- Same as above. sive temperatures. Note:The power output is temperature-sensitive and requires a special procedure to determine its value: 1.Check the pipe temperature under the thermal insulation at several locations. 2.Power the heating cable and allow it to stabilize for 10 minutes,then measure current and voltage at the junction box. 3.Calculate the power(watts/ft)of the heating cable by multiplying the current by the voltage and dividing by the actual circuit length. Power(watts/ft)= Current(A)x Voltage(Vac) Length(ft) THERMAL MANAGEMENT SOLUTIONS EN-RavchemHAKC 100-IM H565'1 01/13 13/16 FM Required Division 1 Installation Record To complete the FM approval process,fill out this form and return it to the Pentair Thermal Management Customer Service Center(fax number)6501361-6711). Company Name Purchase Order No. Reference Drawing's) Circuit ID No. Initials Test Value/Remarks Date AREA: GROUND-FAULT EQUIPMENT PROTECTION: Auto-ignition temperature[AIT) Make and model Group classification Ground-fault equipment protection device trip level ImA I INSTALLATION INSTRUCTIONS: Heating cable type Correct components per manufacturer's specification Supply voltage Seal fittings opened and inspected(properly poured) Circuit length Ground-leakage device tested Maximum pipe temperature Heat temp.identification number(T-rating) COMPONENTS: GROUND-FAULT EQUIPMENT PROTECTION: Power connection Make and model End seat Ground-fault equipment protection device trip level'mA) Tee connection Spice INSTALLATION INSTRUCTIONS: Correct components per manufacturer's specification Seal fittings opened and inspected(properly poured) Ground-leakage device tested INSULATION RESISTANCE TESTING: Minimum insulation resistance must be 1000 m0.If less than 1000 mU see Troubleshooting Guide(pages 12 and 13). Heating Cable Test 1 (refer to Step 16a and b of HAK-C-100 installation instructions) Instrument used: Calibration due date: Measured BEFORE thermal insulation is installed: 500 Vdc 1000 Vdc 2500 Vdc Date: Insulation Resistance Test A(0) Date: Insulation Resistance Test B(0) Post-Thermal-Insulation Heating Cable Test 2(refer to Steps 21 and 16b of HAK-C-100 installation instructions) Instrument used: Calibration due date: Measured AFTER thermal insulation is installed: 500 Vdc 1000 Vdc 2500 Vdc Date: Insulation Resistance Test A(U) Date: Insulation Resistance Test B(0) Circuit Ready to Commission Prepared by Company Date Approved by Company Date THERMAL MANAGEMENT SOLUTIONS EN-RaychernHAKCIO0-IM-H56573 01/13 14/16 Page Left Blank Intentionally THERMAL MANAGEMENT SOLUTIONS I EN-RavchemHAKC100-IM-F156573 01/13 15/16 00 PENTAIR WWW.THERMAL.PENTAIR.COM NORTH AMERICA EUROPE,MIDDLE EAST,AFRICA ASIA PACIFIC LATIN AMERICA Tel: +1.800.545.6258 Tel: +32.16.213.511 Tel: +86.21.2412.1688 Tel: +55.11.2588.1400 Fax: +1.800.527.5703 Fax: +32.16.213.603 Fax: +86.21.5426.2917 Fax: +55.11.2588.1410 Tel: +1.650.216.1526 thermal info@pentaircom cn.thermaLinfo@pentaircorn thermaLinfo@pentair.com Fax: +1.650.474.7711 thermaLinfo@pentair.com Pentair,HAK,LBTV,VPL.BTV, FHP,HBTV,OTVR,HOTV,XTV,and HXTV are owned by Pentair or Ls global affiliates.All other trademarks are the property of their respective owners.Pentair reserves the right to change specifications without prior notice. iitcia 1999-2013 Pentair, PN 589233-000 THERMAL MANAGEMENT SOLUTIONS I EN-RavchemHAKC100-1M-H56ov3 01/13 16/16