Terminator ZT/FAK-4 and FAK 4L
Thermostat Connection In-Line Power Kit For Use With TubeTrace® Bundles
INSTALLATION PROCEDURES
[Thermon Logo]
Introduction
The following installation procedures are suggested guidelines for the installation of the Terminator ZT/FAK-4 and FAK 4L Thermostat Connection In-Line Power Kit.
Receiving, Storing and Handling
- Inspect materials for damage incurred during shipping.
- Report damages to the carrier for settlement.
- Identify parts against the packing list to ensure the proper type and quantity has been received.
- Store in a dry location.
Dimensions
| Model | A (mm/inch) | B (mm/inch) | C (mm/inch) |
|---|---|---|---|
| Terminator ZT/FAK-4 | 279 mm (11") | 289 mm (11-3/8") | 185 mm (7") |
| Terminator ZT/FAK-4L | 489 mm (19-1/4") | 305 mm (12") | 185 mm (7") |
Terminator ZT/FAK-4 and FAK-4L Kit Contents
| Item | Quantity | Description |
|---|---|---|
| 1 | 1 | Expediter Assembly: Flat Mount Base, Grommet, Threaded Grommet Compressor, and Support Cap with O-Ring |
| 2 | 1 | Junction Box Lid |
| 3 | 1 | Junction Box Base with O-Ring and M25 Dust Cap |
| 4 | 1 | Expediter Nut |
| 5 | 1 |
Thermostat w/ Terminal Blocks (Refer to terminal specifications for maximum allowable wire size) Thermostat Type | Control Range ZT-C-100 | 0°C to +100°C ZT-C-200 | 0°C to +200°C ZT-C-300 | 0°C to +300°C ZT-C-500 | 20°C to +500°C |
| 6 | 1 | Junction Box Cord |
| 7 | 1 | In-Line Splice Cover (Top) |
| 8 | 1 | In-Line Splice Cover (Bottom) |
| 9 | 1 | Heat Reflective Tape |
| 10 | 3 | RTV Sealant Tube |
| 11 | 1 | Glass Fiber Tape |
| 12 | 1 | Silicone Gasket |
| 13 | 1 | Self-Vulcanizing Tape |
| 14 | 1 | Blind Plug |
Required: Order Separately for each heater to be fabricated.
PETK Power and End Termination Kits (one req'd. per heater)
- PETK-1 for BSX, RSX, VSX-HT
- PETK-2 for KSX, HTSX
- PETK-3-ZT for FP, HPT
Tools Required
- Terminator-LN-Tool (order separately)
Terminator ZT Certifications/Approvals
IP66 -60°C ≤ Ta ≤ +50°C T5, 100°C; -60°C ≤ Ta ≤ +40°C T6, 85°C Ordinary & Hazardous Locations
IECEx FMG 10.0022X Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C
CE 1725 Ex II 2 GD Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C FM10ATEX0058X
Product Overview
The Terminator ZT/FAK-4 and FAK-4L Thermostat In-Line Power Kit is designed to provide accurate control with the ZT thermostat and make a waterproof seal over the end of TubeTrace and terminate Thermon electric heat trace in an approved Terminator junction box. Review Instructions prior to installation. Kit will make one connection.
Installation Precautions
- Keep ends of bundles, heat tracing and kit components dry before and during installation.
- To minimize the potential for arcing on electrical heat tracing caused by product damage or improper installation, use appropriate ground-fault circuit protection.
- Installation must comply with Thermon requirements and be installed in accordance with any applicable national and local codes.
- Component approvals and performance ratings are based on the use of Thermon specified parts only. User supplied power connection fittings must be listed or certified for intended use.
- De-energize all power sources before opening enclosure.
- Individuals installing these products are responsible for complying with all applicable safety and health guidelines. Proper personal protective equipment, or PPE, should be utilized during installation. Contact Thermon if you have any additional questions.
Installation Procedures
Step 1: Prepare Tubing Bundle
Remove outer jacket and insulation from tubing bundle approximately 457 mm (18") from the end of the tubing bundle.
CAUTION: Do not cut or damage the heat trace or sampling tube. (Found on TubeTrace SE/ME bundles)
Diagram shows a tubing bundle with outer jacket and insulation being removed from the end.
Step 2: Trim Tubing (Self-Regulating Heat Tracing)
Trim tubing to within 38 mm (1-1/2") of the end of the insulation. If self-regulating heat trace, proceed to step 3. For Zone-type heat trace, continue with identification of bus connection on step 2a.
Diagram shows tubing trimmed, with heat tracing visible.
Step 2a: Prepare Zone-Type Heat Tracing
Strip back bundle insulation 38 mm (1-1/2") to 76 mm (3") beyond the bus connection indentation of each heat tracing. If the bus connection indentation is less than 305 mm (12") to 381 mm (15") from the end of the heat tracing, proceed stripping the bundle insulation to the next indentation. Trim tubes so the bus connection indentation on each meet.
Diagram shows heat tracing with insulation stripped back to reveal bus connection indentations, and tubes trimmed to meet.
Step 3: Make Tube Fitting Connections
Make tube fitting connections with appropriate fittings (provided by others). Test fittings for leaks before proceeding.
Diagram shows tube fittings connecting to the heat tracing.
Step 4: Cut Cable Ends
Cut the ends of the cable at an angle to aid in piercing the grommet.
Close-up diagram shows cable ends being cut at an angle.
Step 5: Prepare Splice Cover and Base
Cut splice cover ends to match the outside diameter of the tubing bundle. Field drill expediter base holes (by others).
Diagram shows splice cover pieces and indicates field drilling for expediter base holes.
Step 6: Route Components and Mount Expediter Base
Route the thermostat bulb through the expediter nut and expediter opening in the junction box base. If necessary, apply lubricant (user supplied) to the end of the thermostat bulb. Slide through the conical grommet hole. Insert the tracing cables through the conical grommet holes and punch out the weep hole. Mount the expediter base with the o-ring to the splice cover base using three (3) M5 mounting screws and lock washers.
Exploded view diagram shows how the thermostat bulb, tracing cables, expediter, and junction box base connect. It also shows the mounting screws.
Step 7: Install Thermostat Sensor
Create a gap between the insulation and the tube with a screwdriver for the sensor and place the sensor inside.
Diagram shows a screwdriver creating space for the thermostat sensor.
Step 8: Apply Heat Reflective and Glass Fiber Tape
Wrap tube and heat trace with 1 pass of reflective tape (25% overlap), then wrap with 3 passes of glass fiber tape (50% overlap), or until the fiber tape is equal to the original bundle insulation thickness.
Diagram shows wrapping with reflective tape and glass fiber tape.
Step 9: Apply Additional Reflective Tape
Complete with additional passes of heat reflective tape.
Diagram shows additional heat reflective tape being applied.
Step 10: Install Silicone Gasket and Seal
Install silicone gasket and cut off excess. Apply RTV sealant to both halves.
Diagram shows a silicone gasket being placed and RTV sealant applied.
Step 11: Assemble Splice Cover
Assemble splice cover top, tubing bundle, and splice cover base together as shown. Snap together firmly. Inspect ends of tubing splice cover for snug fit. Apply additional RTV sealant where needed.
Diagram shows the splice cover components being assembled.
Step 12: Apply Self-Vulcanizing Tape
Apply self-vulcanizing tape around the bundle jacket and work up over FAK ends.
Diagram shows self-vulcanizing tape being applied.
Step 13: Trim Heat Tracing
Trim heat tracing to 180 mm (7") minimum from the expediter base.
Diagram shows heat tracing being trimmed.
Step 14: Terminate Heat Tracing
Terminate heat tracing with appropriate PETK termination kit. Refer to PETK installation instructions (purchase separately) for details not addressed here.
Diagram shows the end of heat tracing with a power connection boot.
Step 15: Mount Junction Box
Mount junction box on expediter making sure to align slots to properly orient the junction box base. Tighten nut with Terminator-LN-Tool.
Diagram shows the junction box being mounted onto the expediter, with alignment slots highlighted.
Step 16: Install Power Gland and Blind Plug
Remove M25 dust cap. Install M25 power gland (order separately) and M25 blind plug.
Diagram shows the M25 dust cap removed, ready for gland/plug installation.
Step 17: Install Thermostat and Wiring
Install thermostat and complete system wiring. Terminal set screws shall be tightened to a torque value of 1.4 Nm (12.4 lb-in). See step 17 for wiring details. Set thermostat at desired setpoint.
Diagram shows the inside of the junction box with the thermostat and wiring terminals.
Step 18: Wiring Details
Thermostat Connection (1 or 2 Heating Cables)
Wiring Diagram: Power Supply (L1, N, PE) connects to Thermostat terminals (L, N, PE). Two heating cables are shown connected to the thermostat.
Wiring diagram illustrating connections for power supply and heating cables to the thermostat.
Step 19: Install and Tighten Junction Box Lid
Install junction box lid and twist hand tight. Insert screwdriver into ratchet slot located on the side of the junction box base to tighten. Use screwdriver ratchet on the junction box lid. The lid will rotate 30°. To remove lid, repeat steps but in the opposite direction.
Diagram shows the junction box lid being installed and tightened with a screwdriver in a ratchet slot.
Step 20: Completed Assembly
Completed Terminator ZT/FAK-4/4L power/thermostat assembly for TubeTrace Type SE/ME Bundle. (Installation shown is to feed power in the middle of a TubeTrace bundle. Many installations will be near the end of a TubeTrace bundle.) Install bundle clamps (order separately) 300 mm before and after the In-line power kit.
Diagram shows the completed assembly attached to a TubeTrace bundle, with indications for bundle clamp placement.
