Power Connection Kit installation instructions

Transcription

1 Operating instructions & Parts Manual ET00 Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. Power Connection Kit installation instructions Description The ET00 plug-in power connection kit is suitable for use only with the PSLL and PSL series heating cables. The kit provides material for one power connection. The PSLL and PSL series cables can be used for pipe freeze protection and/or roof and gutter de-icing. Assembly Tools Needed Utility knife, wire cutter, needle-nose pliers, adjustable wrench, pen, screwdriver, heat gun, and measuring tape. Other Material Required - Certified junction box appropriate for the site. - ET03 tape for pipe applications; ET13/ET14 roof clips and/or ET15 downspout hangers for roof and gutter de-icing. General safety information Read and understand all instructions in this manual and the following installation instructions and Safety Warnings. Electrical cables, if not installed correctly or are damaged, can present a fire, shock, and arcing hazard. 1. Installation must be in compliance with National Electrical Codes (NEC). 2. Use 30-mA ground fault protection on each heating cable branch circuit for maximum protection. Kit items 3. The black heating-cable core is conductive and can short. It must be properly insulated and kept dry. 4. The conductive layer of this heating device must have a suitable grounding/earthling terminal. 5. Installer should apply the nameplate label to surface of the junction box. 6. Keep components and ends of heating cable dry before installation. 7. Do not break braid or bus wire strands when scoring the jacket or core. Damaged bus wires can overheat or short. 8. Keep bus wires separated. Bus wires will short if they touch each other. 9. Replace damaged parts. Heatdamaged components can short. 10. Use heat gun or torch with a soft, yellow, low-heat flame, not a blue flame. Keep the flame moving to prevent overheating or blistering the heat-shrinkable tubes. item description qty. Black Shrinkable Tubing (1/8 2 B Green/Yellow Shrinkable Tubing (1/4 1 C Fitting and Black 1 D Lock 1 Black Shrinkable Tubing (1/2 1 Gasket 1 G Black 1 H Wire 3 I Labels 4 Bracket for 1 Approved 46DV pipe heating cable & 4FB1 de-icing and snow melting equipment Figure 1 Power Kit ET Do not heat other components. 12. Use only fire-resistant insulation materials such as fiberglass wrap. 13. De-energize all circuits before installation or service. 14. The heating cable should not be embedded in insulation or roofing material. 15. Do not twist cable during installation. 16. Save all instructions for future reference. Charring or burning the heat-shrinkable tubes in this kit will produce fumes that may cause eye, skin, nose, and throat irritation. C A B Figure 2 D E F G H J I

2 Power Connection Kit installation instructions Pipe Freeze Protection Heating Cable Selection(PSL series) Table 1 PSL self-regulating heating cable for METAL pipes with fiberglass insulation or equivalent (based on 40 F constant temperature with a 10% safety factor). lowest Nominal Pipe sizes Air Temp. insulation 1/2 3/4 1 1¼ 1½ 2 2½ F 1/2 3 W/ft. 3 W/ft. 3 W/ft. 3 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 8 W/ft. 8 W/ft ½ F 1/ ½ F 1/ ½ Table 2 PSL self-regulating heating cable for PLASTIC pipes with fiberglass insulation or equivalent (based on 40 F constant temperature with a 10% safety factor). lowest Air Temp. insulation 1/2 3/4 1 1¼ Nominal Pipe sizes 1½ 2 2½ F 1/2 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 5 W/ft. 8 W/ft. 8 W/ft. 10 W/ft.10 W/ft ½ F 1/ ½ F 1/ ½ Model Information

3 Model ET00 Pipe Freeze Protection Attaching Heating Cable to Pipe 1. Prior to installing the cable, be sure all piping is dry, and any sharp surfaces are removed. 2. The cable must be installed 10 inches away from combustible surfaces, such us wood. 3. The minimum bending radius of each flexible heating device is 1/2 inch. 4. Cut the cable to length needed. Do this before or after the cable is attached to the pipe. 5. Provide for a minimum of 1 foot extra heating cable to connect to power or for splices and tees. 6. Attach heating cable to pipe with straight, spiraling or multiple tracing. 7. If the heating cable is the same length as the pipe, run it straight along the bottom of the pipe. If two cables are required, position them in the 4 and 8 o clock positions. If three cables are required, position them in the 11 o clock or 1 o clock positions and 4 o clock and 8 o clock positions. 8. If the cable is less than double the pipe length, spiral the cable over the length of pipe. Table 3 Maximum PSL series heating Cable Circuit length 9. Any excess cable remaining at the end of the pipe can be doubled back along the pipe. 10. Be sure to include any additional heating cable required for valves, spigots, etc. 11. Secure the cable to the pipe with ET03 fiberglass application tape or nylon cable ties. DO NOT use vinyl tape, metallic products or wire. 12. Install all end seals, splices, tees and power connection prior to plugging in. 13. Protect the heating cable ends from moisture or mechanical damage if they will be left exposed before connection. Install Thermal Insulation 1. Before insulating, inspect the cable to ensure that it is free of mechanical damage, such as gouges or cuts, etc. 2. Cover the pipe, cables, connections, valves with at least 1/2 (12.7 mm) thick fiberglass insulation or equivalent. DO NOT leave the cables exposed. 3. Use fire-resistant materials such as fiberglass wrap. Make sure the insulation is waterproofed (with polyethylene or other vapor barriers) Maximum Circuit length (in Feet) Circuit Breaker for Ambient Temperature of 0 C 3PSL 20 A PSL PSL PSL PSL NOTE: Circuit breaker sizing is based on Section 427 of the National Electrical Code. Maximum circuit lengths are based on start-up load. Steady-state amps per foot depends on heating cable temperature. in areas where water may come in contact with the insulation. 4. Place the two warning labels on the outer surface of the pipe insulation where clearly visible and at suitable locations to indicate the presence of electric heating cable. Maintenace Checks 1. Only qualified persons should service or install the system. 2. Check yearly for any damage to the heating cable and check any ground fault protection device for proper operation. If any damage to cable is found, DO NOT operate until it is replaced. 3. Use a 2500 Vdc megohmmeter (500 Vdc minimum) to test the insulation resistance between the bus wire and the heater ground wire or pipe. The reading should be 20 megohms, without regard to length. Roof and Gutter de-icing heating Cable selection (PSL-CR series) 1. Calculate the total length of cable required by adding the Total roof edge length (ft.) (x feet of heating cable per foot of roof edge, see table 4), the Total gutter length (ft.), and the Total downspout length (ft.) (+1 ft.). Also add one foot for each power connection, and three feet for each tee connection. NOTE: The roof edge length (ft.) x feet of heating cable required per foot of roof edge equals the Total roof edge cable length required. 2. For Standard roofs, add 1 foot of heating cable for each foot of gutter. 3. Add 1 foot of heating cable per foot of downspout.

4 Power Connection Kit installation instructions Roof and Gutter De-icing Standard Roof Metal Roof 4. If downspout in is in the middle of the gutter run, loop the cable down and back. Double the length of the downspout for determining the length of the cable to install. 5. For roof valleys, run the heating cable two thirds of the way up and down the valley. Add this additional length to the overall cable length. 6. The circuit length for a given overcurrent protection device shall Figure 3 not exceed the maximum length specified by the manufacturer. example (standard roof): Roof Edge length ft. (with Roof overhang of 1 ft.) Gutter length ft. Downspout length ft. Power connection... 2 ea. Tee connection... 1 ea. Voltage available V Heating cable... 5PSL2-CR length of heating cable required: Roof Edge length ft. ( 2) (see table below) Gutter length ft. Downspout length (+1) ft. Power connection... 1 ft. x 2 ea. Tee connection... 3 ft. x 1 ea. Total ft. Roof Clip Hanger Bracket Installation Of De-icing Cables For Roof, Gutters And Downspouts Use only the following kits and accessories to satisfy code and agency requirements: - ET08 Plug-in Power Connection Kit - ET10 Splice and Tee Kit (if splicing or teeing) - ET12 End Seal Kit - ET15 Downspout Hangers - ET13/ET14 Roof Clips 1. Carefully plan the routing of the heating cable for roof and gutter de-icing. 2. Route the heating cable to avoid mechanical damage from ladders, etc. 3. Cut the heating cable to proper length. This can be done before or after the cable is on the pipe. Roof Clips Hanger Bracket 4. Before installing the heating cable, make sure the roof, gutter and downspouts are free from debris, leaves, pine needles or any combustibles. 5. Check the maximum exposure temperature rating of all roof, gutter and downspouts, and select a heater that will not exceed their temperature ratings. 6. The minimum installation temperature is 0 F (-18 C). 7. The heating device shall be connected to non heating leads of a weatherresistant type. The installer should protect the non heating leads from damage by installing them in a rigid metal or nonmetallic raceway. Table 4 Typical spacing and layout Measurements Feet of heating Cable per Foot of roof edge Cable loop height Roof Overhang Shingle Roof Metal Roof (24 ) Shingle Roof Metal Roof None

5 Model ET00 Roof and Gutter de-icing 8. Use hanger bracket to support the heating cable where it enters a downspout to prevent cable from being damaged by gutter edge. It also can be used as a spacer in wider gutters. 9. Run heating cable over top of hanger and secure to hanger using UV resistant cable ties. 10. Use roof clips for attaching the heating cable to the roof. 11. For roof valleys, run the heating cable two thirds of distance up and down the valley. Add the additional length to the overall cable length. 12. Protect the heating cable ends from moisture or mechanical damage before connection. 13. Field assembled end terminations should not be located in an area where moisture is present or, at the lowest point of downspouts. 14. Install end seals, splices, tees and power connection before plugging in. Follow all ET00 kit installation instructions. 15. Use only listed weatherproof junction boxes approved for wet locations when installing PSL-CR series heating cables with the ET00 Power Connection Kit. 16. Use only listed watertight construction or enclosure Type 3, 3s, 4, 4X, 6, or 6P junction box when installing. 17. Attach the two warning labels (included with the heating cable). The labels must be clearly visible on the premises. Table 5 Maximum PSL-CR series heating Cable Circuit length Maximum Circuit length (in Feet) Circuit Breaker for Ambient Temperature of 0 C 3PSL-CR 20 5PSL-CR PSL-CR The heating device shall be connected to nonheating leads of a weather-resistant type. The installer should protect the nonheating leads from damage by installing them in a rigid metal or nonmetallic raceway. Maintenance Checks 1. Only qualified persons should service or install the system. 2. Check yearly for any damage to the heating cable and check any ground fault protection device for proper operation. If any damage to cable is found, DO NOT operate until it is replaced. 3. With a 2500 Vdc megohmmeter (500 Vdc minimum) test the insulation resistance between the bus wire and the heater grounding braid or metal pipe. The reading should be 20 megohms at any length of cable. NOTe: Circuit breaker sizing is based on Section 427 of the National Electrical Code. Maximum circuit lengths are based on start-up load. Steady-state amps per foot depends on heating cable temperature. Table 6 Product data for PSL-CR series heating Cables for roof and Gutter de-icing Model service Voltage Thermal F (in ice & snow) Min. installation Temp. Max. exposure Temp. Chemical exposure Environmental Restrictions 3PSL1-CR 120V 6 Watts/ft. 0 F 185 F Aqueous inorganic Nonhazardous & hazardous 3PSL2-CR Aqueous inorganic Nonhazardous & hazardous 5PSL1-CR Aqueous inorganic Nonhazardous & hazardous 5PSL2-CR Aqueous inorganic Nonhazardous & hazardous 8PSL1-CR Aqueous inorganic Nonhazardous & hazardous 8PSL2-CR Aqueous inorganic Nonhazardous & hazardous

6 Power Connection Kit installation instructions Power Connection Kit installation instructions 5. Place braid onto one side of heating cable. Cut inner jacket of cable back 6 (152mm). Figure 9 Figure 4 NOTe: Instructions generally show heating cable with braid and outer jacket. Cables with no outer jacket look slightly different from those illustrated. 6. Shave off outer matrix material from conductors with utility knife. See Figure Open the sealing fitting and slide the junction box fitting cap, strain relief disk, grommet, and fitting body onto the power connection end of cable. 3. Gently push braid back to loosen and spread apart braid as shown. Figure 5 2. Score completely around heating cable outer jacket, and then score down a distance of 7 (178mm), being careful not to cut braid or inner jacket. Then, bend heating cable to break jacket at score, and peel off outer jacket. Figure 7 4. Bend heating cable enough to work it through the braid opening. Figure Peel back exposed wires from central matrix material. See Figure 11. do not cut bus wire strands! Figure 8 Figure 11 Figure 6

7 Model ET00 Power Connection Kit installation instructions 8. Cut off remaining center core of matrix; leaving the bare conductors. do not cut bus wires! 11. Then, insert green/yellow tube over braid and shrink. 14. While tube is still hot, pinch tube with pliers, between wires, and hold for 10 seconds to ensure seal. See Figures 18 & 19. Figure Slip on black shrink tubes 5½ (140mm) in place up to conductive core. Figure Center black shrink tube 1 (25mm) over end of heating cable as shown in Figure 16. Figure 18 Figure Carefully shrink tubing by moving heat source from side to side continuously; being careful not to damage heating cable. Figure Heat tube evenly until it shrinks and adhesive flows out both ends. Figure For heating cables with an outer jacket, slide parts in place as shown below. Figure 14 Figure 17 Figure 20

8 Power Connection Kit installation instructions Power Connection Kit installation instructions 16. Slide parts in place. For heating cables without an outer jacket, see Figure 21; with outer jacket, see Figure Use a metallic junction box to ensure a proper ground. Insert heating cable and tighten. NOTE: For PSL2-CR heating cables When used in wet locations, follow instructions provided with junction box to seal out water. NOTE: Allow at least 6 of lead wire inside an outlet box. Figure 25 For heating cables with outer jacket, see Figure 26. Figure 21 Figure Loosely attach the metal pipe mounting bracket to the pipe with the metal band. Position the bracket so that the cable and fitting come straight up and through the hole. Then tighten the band. Figure Make connections as shown in Figures 25 & 26. Connect the power conductors to the cable leads. Connect the incoming supply ground to the cable braid and to the green ground wire. The wire nuts, included, are not for use with aluminum feed wires. The junction box needs to be grounded. For heating cables without outer jacket, see Figure 25. Figure For roof and gutter applications, put warning label on junction box. See Figure 27. Figure 23 Limited Warranty Figure 27 All products sold are warranted by Drexma only to customers for resale, or for use in business, or original equipment manufacture, against defects in workmanship or materials under normal use for one year after date of purchase from Drexma.