eltherm ELAK-RS & ELAK-RS-T Junction Box Operation Manual
Document Number: QAA-113, Revision 1
Introduction
This manual provides instructions for the proper and safe use of eltherm ELAK-RS and ELAK-RS-T junction boxes. It is intended for persons trained in handling electrical equipment and covers installation, operation, and maintenance.
Please keep these instructions for future reference, for example, in the system documentation.
Display Conventions
Important points in these instructions are indicated by the following symbols:
- [DANGER]: Refers to an extremely dangerous situation. If not prevented, there is a risk of death or at least a high risk of serious injuries.
- [ATTENTION]: Refers to a potentially dangerous situation. If not prevented, there is a risk of danger or malfunction.
- [WARNING]: Refers to a dangerous situation. If not prevented, there is risk of injury or at least a high risk of material damage.
- [NOTE]: Important information and instructions for safe, effective, and environmentally compatible usage.
Receipt of Goods
Upon receipt, check the junction boxes and accessories against the information on the delivery note to ensure the correct material has been delivered.
Storage
[NOTE] Storage should be in a dry, clean place at an ambient temperature from 0°C to 50°C.
Disposal
[NOTE] The WEEE logo indicates that this product should not be disposed of with other waste. For more information on the disposal and recovery of waste electrical and electronic equipment (WEEE) and collection points, please contact your local waste disposal company or the manufacturer.
Technical Data
| Feature | ELAK-RS (0920050) | ELAK-RS-T (0920059) |
|---|---|---|
| Junction box | ||
| Nominal voltage (max.) | 800 V AC | 800 V AC |
| Nominal current | max 32 A per terminal 6 mm² | max 32 A per terminal 6 mm² |
| Ambient temperature | -45 °C to +50 °C | -45 °C to +50 °C |
| Nominal cross-section* | Supply line max. 6 mm², 9-17 mm diameter | Supply line max. 6 mm², 9-17 mm diameter |
| Material enclosure | Polyamide, RAL 7043 traffic grey | Polyamide, RAL 7043 traffic grey |
| Dimensions | (approx.) Ø 154.5 mm, height 125 mm | (approx.) Ø 154.5 mm, height 125 mm |
| Protection level | IP 65 | IP 65 |
| Operation temperature mounting post | max. +200 °C | max. +200 °C |
| Material mounting post | PPS | PPS |
| max. insulation thickness | 100 mm | 100 mm |
| min. pipe diameter | ≥ NW3/4" / AD 20 mm | ≥ NW3/4" / AD 20 mm |
| Weight | approx. 0.7 kg | approx. 0.7 kg |
* Connection cross-section (solid or with fine wires without wire end ferrule); terminal heating cable max. 6 mm² (AWG10); Terminal temperature sensor max. 2.5 mm² (AWG 13)
Dimensions
The junction box has a diameter of approximately 154.5 mm and a height of 125 mm. The overall height including the mounting post is approximately 266 mm, with the main enclosure body being approximately 123 mm high.
Scope of Delivery & Connection Plan
ELAK-RS
Internal View: The ELAK-RS junction box features terminal blocks for power and sensor connections, including a terminal for earthing or electrical protection.
| Type | Qty. | Clamp range |
|---|---|---|
| Blind plug M20x1,5 | 1 | |
| Cable gland M20x1,5 * | 1 | 9-12 mm |
| Blind plug M25x1,5* | 1 | |
| Cable gland M25x1,5 | 1 | 9-13/12-17 mm |
| Protective earth terminal | 1 | 2.5 mm² |
| Double-deck terminal | 2 | 2.5 mm² |
| 4-wire Protective earth terminal | 1 | 4 mm² |
| 4-wire Feed-through terminal | 2 | 4 mm² |
* loosely enclosed
ELAK-RS-T
Internal View: The ELAK-RS-T junction box also features terminal blocks for power and sensor connections, including a terminal for earthing or electrical protection.
| Type | Qty. | Clamp range |
|---|---|---|
| Blind plug M20x1,5 | 1 | |
| Cable gland M25x1,5 | 2 | 9-13/12-17 mm |
| Blind plug M25x1,5* | 1 | |
| 4-wire Protective earth terminal | 2 | 4 mm² |
| 4-wire Feed-through terminal | 4 | 4 mm² |
* loosely enclosed
Connection Plan
ELAK-RS Wiring Diagram: Shows connections for Line (L), Neutral (N), Protective Earth (PE), and sensor terminals, illustrating the integration of a heating cable and a sensor.
ELAK-RS-T Wiring Diagram: Similar to ELAK-RS, it depicts connections for L, N, PE, and sensor terminals, accommodating a heating cable and a sensor.
Installation
Safety Instructions
[ATTENTION] The following steps should only be carried out by persons trained in handling electrical equipment. Strict compliance with relevant standards and safety regulations is required for the safety of persons, plants, and equipment. Those entrusted with planning, installation, and maintenance must be thoroughly familiar with applicable regulations.
Recommended Tools
The manual illustrates various tools required for installation, including pliers, screwdrivers, and wrenches.
Placement of ELAK-RS
Step 1: Do not fasten the heating cable and sensor line at the planned measurement point, which is approximately 500 mm from the end of the cable.
Diagram Description: An illustration shows a pipe with a heating cable and sensor cable. A measurement point is marked at approximately 500 mm from the cable end.
Assembly Instructions
[ATTENTION] When selecting the mounting location, consider the degree of mechanical danger to the junction box and cable entries, as well as the permissible ambient temperature. Ensure the mounting surface is load-bearing. Cables must be laid firmly and secured against pulling out of the cable entry (e.g., by a cable clamp). Unused clamping points must be tightened. Before inserting blind plugs or conduit entries, ensure threaded boreholes are clean and undamaged. After connection, all openings (cover, boreholes, cable entries) must be closed tightly using appropriate spanners. The lid is designed for customer identification plates, secured with Ø 2.2 x 6 mm screws.
Step 2: Prepare the end of the sensor line with a strong wire and adhesive tape to guide it into the mounting base.
Diagram Description: An illustration shows the end of a sensor line being prepared with a wire and tape for insertion.
Step 3: Lead a sensor line into the provided opening and pull approximately 200 mm into the mounting base.
Diagram Description: An illustration shows a sensor line being fed into an opening and pulled about 200 mm into the mounting base.
Step 4: Remove the adhesive tape and strong wire from the sensor line.
Diagram Description: An illustration shows the removal of adhesive tape and a guiding wire from a sensor line.
Step 5: Cut the end of the heating cable at an angle of approximately 45°.
Diagram Description: An illustration shows the end of a heating cable being cut at a 45-degree angle.
Step 6: Guide the heating cable into the mounting stand.
Diagram Description: An illustration shows a heating cable being guided into a mounting stand.
Step 7: Guide the heating cable approximately 200 mm through the mounting stand.
Diagram Description: An illustration shows a heating cable being guided approximately 200 mm through a mounting stand.
Step 8: Fasten the mounting stand onto the pipe with a strap. Ensure the tightening strap is not positioned above the heating cable or sensor cable.
Diagram Description: An illustration shows a mounting stand being fastened to a pipe with a strap, with a caution regarding the strap's placement relative to the cables.
Step 9: Mount the heating cable connection (not included with delivery).
Diagram Description: An illustration shows a heating cable connection being mounted.
Open the Junction Box
Step 10: Tighten the headless screw with an Allen wrench (size 2) until the locking arm is flush with the side bars.
Diagram Description: An illustration shows a headless screw being tightened with an Allen wrench.
Step 11: Insert a flat-tip screwdriver between the locking arm and the rear bar, and push the locking arm forward a few millimeters by turning the screwdriver.
Diagram Description: An illustration shows a flat-tip screwdriver being used to adjust a locking arm.
Step 12: Turn the headless screw back with the Allen wrench (size 2) until it is protruding slightly out of the locking arm.
Diagram Description: An illustration shows a headless screw being loosened.
Step 13 & 14: Open the lid using a screwdriver.
Diagram Description: Illustrations show a lid being lifted and then opened using a screwdriver.
Fasten the Junction Box
Fasten the mounting post [ELAK-RS] to the pipe with a tension strap or turnbuckle.
Assembly Accessories for Pipe Mounting (Mat. 1.4301)
| Type | Qty. | Part Number |
|---|---|---|
| Hose clamp 16-25 mm | 2723001016 | |
| Hose clamp 25-40 mm | 2723001025 | |
| Hose clamp 40-60 mm | 2723001040 | |
| Hose clamp 70-90 mm | 2723001070 | |
| Hose clamp 90-110mm | 2723001090 | |
| Strapping tape, 11 mm, 30 m | 2723001010 | |
| Turnbuckle (VE = 10 Stk) | 0930042 |
Connect Heating Cable & PT 100
[ATTENTION] Please observe the respective installation instructions for the sensors or heating cables. Ensure all terminals and cable glands are tightened according to instructions.
Step 15: Attach the housing to the Ex-it mounting post. The housing must engage with an audible click (2x click).
Diagram Description: An illustration shows the junction box housing being attached to a mounting post, with an indication of an audible click for proper engagement.
Strain Relief for Sensor Cable
The sensor cable is secured using a fastening clamp, a nut, and a headless screw (M4x16; DIN913) to provide strain relief.
Diagram Description: A detailed view shows the sensor cable passing through a fastening clamp, secured by a nut and a headless screw (M4x16; DIN913) for strain relief.
Close the Junction Box
Step 1: Visually inspect the housing and cover for damage. The cover can only be inserted in one position due to specific locking arms and twist protection recesses. Move the cover to the appropriate position.
Diagram Description: An illustration shows a visual inspection of the junction box cover and housing, highlighting alignment features.
Step 2: Fasten the cover with the narrower locking arm (without a headless screw) and close the cover.
Diagram Description: An illustration shows the cover being fastened with a locking arm.
Step 3: Use pliers to lock the cover.
Diagram Description: An illustration shows pliers being used to lock the junction box cover.
Check After Installation
[ATTENTION] After installation, perform the following checks:
- Visually inspect junction boxes for mechanical damage. Damaged boxes must not be put into operation and must be replaced.
- Check the plenum box cover and its attachments (cable entries) for tight fit.
- Ensure all threaded openings are fitted with cable entries or blind plugs, which must be firmly tightened and sealed.
Operation & Maintenance
[DANGER] Junction boxes, including loosening cable entries, may only be opened when the system is de-energized and disconnected from the power supply. Damaged junction boxes must not be put into operation.
[ATTENTION] Observe the permissible ambient temperature. Comply with locally applicable safety regulations. Adhere to permissible operating conditions as per 'Technical data' or labeling (voltage, current, operating temperature, maximum ambient temperature, IP protection class). It is recommended to periodically check the integrity and tight fit of cable glands and connected cables. If necessary, retighten cable entries or have damaged components replaced by qualified personnel. Protect junction boxes from damage during repair work on heated system parts. Re-check the plenum box after repair work.
Marking (made by customer)
[NOTE] Customer-side labeling with an identification plate is possible. The lid of the junction box is designed for this purpose, with screw holes of Ø 2.2 x 6 mm.
Diagram Description: An illustration shows the top of the junction box with markings indicating a space for customer labeling, with dimensions for screw holes.
Downloads
This document can also be found on the eltherm website. Please visit the download area.
