Raychem E-100-A High-Profile End Seal Installation Instructions

DESCRIPTION

The Raychem E-100-A is a NEMA 4X-rated end seal kit. It is designed for use with Raychem BTV-CR, BTV-CT, QTVR-CT, XTV(R)-CT, HTV-CT and VPL-CT industrial parallel heating cables. Once installed, the end seal is easily re-entered for maintenance; the heating cable can be accessed without removing the end seal.

These kits may be installed at temperatures as low as -67°F (-55°C), and the maximum ambient temperature of 132°F (56°C). For easier installation, store above freezing until just before installation.

For technical support, call Chemelex at (800) 545-6258.

APPROVALS

Hazardous Locations

• Class I, Div. 2, Groups A, B, C, D
• Class II, Div. 2, Groups F, G
• Class III
• Ex eb IIC T* Gb
• Class I Division 2 (Zone 2**), Groups A, B, C, D
• Class I Zone 2 IIC
• Ex eb IIC T* Gb
• Class I Zone 1 AEx eb IIC T*°C Gb

* For system Temperature Code, see heating cable or design documentation

(1) Except HTV

(2) For HTV-CT only ** Per CE Code Table 18

TOOLS REQUIRED

• Wire cutters
• Utility knife
• Slotted screwdriver or nutdriver

ADDITIONAL MATERIALS REQUIRED

• GT-66 or GS-54 glass cloth tape
• Pipe Strap

OPTIONAL MATERIALS

• Small pipe adapter for 1 in (25 mm) and smaller pipes: Catalog number JBS-SPA P/N E90515-000
• For boot replacement order E-100-BOOT-5/PACK P/N 281053-000

KIT CONTENTS

INSTALLATION INSTRUCTIONS

Step 1

• Allow approximately 24 in (60 cm) of heating cable for installation. For VPL, cut cable 12 in (30 cm) from bus indentation.
• Cut off heating cable end at about 45° for easier insertion.

Diagram: Shows heating cable with approximately 24 inches (60 cm) exposed, and a 12-inch (30 cm) section cut at a 45-degree angle.

Step 2

• Optional: If stand is to be installed on bottom side of pipe, knock out drain hole prior to inserting cable.
• Push 12 in (30 cm) of heating cable through stand. Use cable lubricant if needed.
• Square off cable end with 90° cut.
• Do not attach stand to pipe until step 8.

Diagram: Shows pushing the heating cable through the stand and a note not to attach the stand to the pipe yet.

Step 3

• Determine heating cable type and continue as shown.

Diagram: Illustrates different heating cable types (VPL, BTV/QTVR, XTV(R)-CT, HTV) and directs users to the appropriate next step (4A or 4B).

Step 4A (VPL)

• Lightly score outer jacket around and down as shown (1/8 in or 3 mm).
• Bend heating cable to break jacket at the score, then peel off jacket.
• Remove all exposed braid.
• Lightly score inner jacket around and down as shown (1/2 in or 13 mm).
• Bend heating cable to break jacket at the score, then peel off jacket.
• Un-wind heating element, cut and remove as shown.
• Lightly score and remove clear jacket.
• Cut one bus wire.

Diagram: Detailed steps for preparing the VPL heating cable, including scoring and peeling jackets, removing braid, and cutting the bus wire.

Step 4B (BTV, QTVR, XTVR, HTV)

• Lightly score outer jacket around and down as shown (1/2 in or 13 mm for BTV/QTVR, 1/2 in or 13 mm for XTVR, 1/2 in or 13 mm for HTV).
• Bend heating cable to break jacket at the score, then peel off jacket.
• Remove all exposed braid.

Diagram: Detailed steps for preparing BTV, QTVR, XTVR, and HTV heating cables, including scoring and peeling jackets, and removing braid.

Step 5

• Pull heating cable back through bottom of end seal stand until braid is just visible above strain relief. Use cable lubricant if needed.

Diagram: Shows pulling the heating cable through the end seal stand, with braid visible above the strain relief.

Step 6

• Push boot onto the end of the heating cable until it bottoms out.

Diagram: Shows pushing the boot onto the heating cable.

Step 7

• Install cap; tighten until the slot on the cap and the slot on the stand align.

Diagram: Shows installing and tightening the cap on the end seal stand.

Step 8

• Fasten end seal to pipe with strap. Do not pinch heating cable.
• Install cable tie.
• Loop and tape extra heating cable to pipe.
• Apply insulation and cladding.
• Weather-seal the stand entry.
• Fasten end seal label to insulation.
• Leave these installation instructions with the user for future reference.

Diagram: Shows the completed installation with the end seal fastened to the pipe, cable tie, and insulation.

Step 8A (Adapter for small pipes)

Note: For 1 in (25 mm) and smaller pipes, use adapter (purchased separately) between stand and pipe.

Diagram: Shows the JBS-SPA adapter for small pipes being positioned between the stand and the pipe.

E-100-A RE-ENTRY INSTRUCTIONS

A. Power Off and Preparation

• WARNING: Shock Hazard. Conductors will be exposed. Re-entry should only be performed by qualified personnel. Follow standard electrical lockout procedures before opening end seal.
• Turn off power.
• Clip cable tie and remove.

Diagram: Shows turning off power and clipping the cable tie.

B. Unscrew Cap

• Unscrew cap from end seal stand.

Diagram: Shows unscrewing the cap from the end seal stand.

C. Remove Boot

• CAUTION: Health Hazard. Wash hands after contact with sealant. Consult material safety data sheet VEN 0033.
• Grab black ring and remove boot.

Diagram: Shows removing the boot by grabbing the black ring.

D. Testing

• Test as required.
• Refer to Industrial Heat-Tracing Installation and Maintenance Manual (H57274) for test procedures.

Diagram: Shows a connection to a power source for testing.

E. Inspect and Replace Boot

• Inspect boot. If boot is damaged or sealant appears dry or missing, replace boot. For replacement boots, order kit E-100-BOOT-5/PACK. Otherwise, re-install boot.

Diagram: Shows inspecting the boot and the option to replace it.

F. Reinstall Cap and Tie

• Install cap; tighten until the slot on the cap and the slot on the stand align.
• Install new cable tie.
• Trim excess.

Diagram: Shows installing the cap and a new cable tie.

WARNING: Explosion Hazard

Substitution of Components May Impair Suitability for Class I Division 2 (Zone 2).

Do not disconnect equipment unless power has been switched off or the area is known to be Non-Hazardous.

SAFETY WARNINGS

WARNING

• This component is an electrical device that must be installed correctly to ensure proper operation and to prevent shock or fire. Read these important warnings and carefully follow all of the installation instructions.
• To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Chemelex, agency certifications, and national electrical codes, ground-fault equipment protection must be used. Arcing may not be stopped by conventional circuit breakers.
• Explosion and shock hazard. Do not disconnect while the circuit is live or unless the area is free of ignitible concentrations.

Component Approvals and Performance

• Component approvals and performance are based on the use of Chemelex specified parts only. Do not use substitute parts or vinyl electrical tape.
• The black heating cable core and fibers are conductive and can short. They must be properly insulated and kept dry.
• Bus wires will short if they contact each other. Keep bus wires separated.
• Use only fire-resistant insulation materials, such as fiberglass wrap or flame-retardant foam.
• Leave these installation instructions with the user for future use.

CAUTION: Health Hazard

• Prolonged or repeated contact with the sealant in the end seal boot may cause skin irritation. Wash hands thoroughly. Overheating or burning the sealant will produce fumes that may cause polymer fume fever. Avoid contamination of cigarettes or tobacco. Consult MSDS VEN 0033 for further information.
• CHEMTREC 24-hour emergency telephone: (800) 424-9300
• Non-emergency health and safety information: (800) 545-6258.

AVERTISSEMENT

AVERTISSEMENT

• Ce composant électrique doit être installé correctement pour éviter les risques d'incendie ou de chocs électriques. Lire ces avertissements importants et suivre attentivement toutes les instructions d'installation.
• Pour réduire le danger d'incendie causé par un arc électrique entretenu, si le câble chauffant est endommagé ou mal installé, et pour respecter les exigences de Chemelex et celles des codes applicables, il est impératif d'utiliser une protection par disjoncteur différentiel. Les disjoncteurs ordinaires ne sont pas toujours capables de supprimer les arcs électriques.
• Risque d'explosion. Ne pas débrancher pendant que le circuit est sous tension ou à moins que l'emplacement ne soit exempt de concentrations inflammables.

Approbations et performances des composants

• Les approbations et les performances des composants sont basées sur l'utilisation des pièces Chemelex spécifiées seulement. N'utilisez pas de pièces de rechange ou de ruban isolant en vinyle.
• Le noyau et les fibres du câble chauffant noir sont conducteurs et peuvent provoquer un court-circuit. Ils doivent être correctement isolés et gardés à sec.
• Les fils omnibus endommagés peuvent surchauffer ou subir un court-circuit. Ne brisez jamais les fils omnibus lorsque vous incisez la gaine ou le noyau.
• Maintenez les composants et les extrémités des câbles chauffants secs avant et pendant l'installation.
• Les fils omnibus peuvent provoquer un court-circuit s'ils se touchent. Les garder à l'écart les uns des autres.
• N'utilisez que des matériaux isolants ininflammables, par exemple une gaine de fibre de verre ou de la mousse ignifuge.
• Laissez ces instructions d'installation à l'utilisateur pour qu'il puisse les consulter.

MISE EN GARDE : DANGER POUR LA SANTÉ

• Le contact prolongé ou répété avec le produit d'étanchéité du noyau peut provoquer une irritation de la peau. Lavez-vous les mains soigneusement. La surchauffe et la combustion du produit d'étanchéité produira des vapeurs qui peuvent causer la fièvre des vapeurs de polymères. Évitez la contamination des cigarettes ou du tabac. Consultez la fiche technique santé-sécurité (FTSS) VEN 0033 pour obtenir de plus amples informations.
• Téléphone en cas d'urgence 24 heures sur 24 de CHEMTREC : (800) 424-9300
• Renseignements non urgents en matière de santé et de sécurité : (800) 545-6258