Raychem E-100-L-A

High-Profile Lighted End Seal Installation Instructions

Product Description

The Raychem E-100-L-A is a NEMA 4X-rated end seal kit featuring a light that indicates voltage at the end of the circuit. 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. The end seal allows for easy re-entry for maintenance and access to the heating cable without removing the end seal. The LED indicator light offers excellent visibility. These kits can be installed at temperatures as low as -40°F (-40°C) and up to a maximum ambient temperature of 104°F (40°C). For easier installation, store the kit above freezing until just before installation. The kit is rated for 100 to 277 V. Ensure the voltage rating of the light matches the heat-tracing circuit's voltage.

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

Approvals

The product has received approvals for hazardous locations, including:

FM APPROVED: Class I, Div. 2, Groups A, B, C, D; Class II, Div. 2, Groups F, G; Class III
IECEX: Ex eb mb IIC T* Gb; Ex tb IIIC T***°C Db
The E-100-L-A is IECEx certified for use with BTV-CR/BTV-CT, QTVR-CT, XTV(R)-CT, HTV-CT, and VPL-CT heating cables.
Class I Division 2 (Zone 2), Groups A, B, C, D; Class I Zone 2 IIC
Ex eb mb IIC T* Gb; Class I Zone 1 AEx eb mb IIC T* Gb

Note: For system Temperature Code, refer to heating cable or design documentation. (1) Except HTV. (2) For HTV-CT only.

Kit Contents

Item	Qty	Description
A	1	End seal stand and light assembly
B	2	Insulated parallel crimps
C	1	End seal label
D	1	Cable lubricant
E	1	Cable tie
F	1	Core sealer

Tools Required

Wire cutters
Utility knife
Needle nose pliers
Slotted screwdriver or nutdriver
Panduit CT-100 crimp tool or equivalent

Additional Materials Required

Pipe strap
Raychem GT-66 or GS-54 glass cloth tape

Optional Materials

Small pipe adapter for 1 in (25 mm) and smaller pipes: Catalog number JBS-SPA P/N E90515-000

Installation Instructions

Step 1: Cable Preparation

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.
Apply lubricant for easier insertion into stand.

Diagram showing cable preparation: cutting at 45 degrees, measuring 24 inches (60 cm) or 12 inches (30 cm) for VPL, and applying lubricant.

Step 2: Stand Insertion

Optional: If the stand is to be installed on the bottom side of the pipe, knock out the drain hole prior to inserting the cable.
Slide the heating cable through the stand.
Square off the cable end with a 90° cut.

Diagram showing sliding the cable through the stand and squaring the end.

Step 3: Cable Stripping

Measure exactly 2 ½ in (57 mm).
Lightly score the outer jacket around and down as shown.
Bend the heating cable to break the jacket at the score; peel off the jacket.
Remove all exposed braid.

Diagram illustrating scoring and peeling the outer jacket, and removing braid.

Step 4: Determine Heating Cable Type

Determine the heating cable type and proceed to the corresponding step:

XTV(R)-CT: Go to Step 5A
BTV, QTVR: Go to Step 5B
VPL: Go to Step 5C
HTV: Go to Step 5D

Diagram showing different heating cable types (XTV(R), BTV/QTVR, VPL, HTV) with corresponding step references.

Step 5A: XTV(R)-CT Cable Preparation

Measure exactly 1⅜ in (35 mm). Do not cut bus wires.
Lightly score the inner jacket around and down as shown.
Peel off the jacket.
Cut and remove all fiber strands.
Score and remove the center spacer.
Remove any remaining fiber material from the bus wires.

Diagram illustrating the stripping process for XTV(R)-CT cable.

Step 5B: BTV, QTVR Cable Preparation

Measure exactly 1⅜ in (35 mm). Do not cut bus wires.
Lightly score the inner jacket around and down as shown.
Peel off the jacket.
Notch the core.
Peel the bus wire from the core.
Score the core between the bus wires at the inner jacket.
Bend and snap the core.
Peel the core from the bus wire.
Remove any remaining core material from the bus wires.

Diagram illustrating the stripping process for BTV, QTVR cable.

Step 5C: VPL Cable Preparation

Measure exactly 1⅜ in (35 mm). Do not cut bus wires.
Lightly score the inner jacket around and down as shown.
Peel off the inner jacket.
Unwind the heating element, cut and remove as shown.
Lightly score the clear jacket around and down as shown.
Remove insulation from the ends of the bus wires.

Diagram illustrating the stripping process for VPL cable.

Step 5D: HTV Cable Preparation

Measure exactly 1⅜ in (35 mm). Do not cut bus wires.
Score the inner jacket and conductive core around and down as shown.
Flip the cable 180° and score the other side of the inner jacket and conductive core.
Remove the inner jacket and conductive core using needle-nose pliers as shown.
Score and remove the center insulation.
Remove any remaining material from the bus wires.

Diagram illustrating the stripping process for HTV cable.

Step 6: Jacket Marking

Mark the jacket as shown.

Diagram showing marking the jacket.

Step 7: Bus Wire Preparation

CAUTION: Health Hazard. Wash hands after contact with sealant. Consult material safety data sheet VEN 0033.
AVERTISSEMENT: risque pour la santé. Se laver les mains après tout contact avec le produit d'étanchéité. Consulter la fiche de données de sécurité VEN 0033.
If needed, re-twist and straighten bus wires, then insert bus wires into guide tubes as shown. Make sure all strands go into the tubes.
Remove the guide tubes and dispose of them in a plastic bag.

Diagram showing bus wire preparation, inserting into tubes, and removing tubes.

Step 8: Core Sealer Application

Push the core sealer onto the heating cable to the mark made in step 6. Note: Extra force may be required for larger cables or at lower temperatures. Make sure the bus wires do not kink, bunch, or crossover.

Diagram showing pushing the core sealer onto the cable.

Step 9: (No specific action described, likely part of previous step's diagram)

Step 10: Cable Insertion into Stand

Pull the cable back through the end seal stand until the braid is just visible above the strain relief.

Diagram showing pulling the cable back through the stand.

Step 11: Conductor Trimming

Trim exposed conductors.

Diagram showing trimming exposed conductors.

Step 12: Securing to Pipe

Fasten the end seal stand to the pipe with a pipe strap. Do not pinch the heating cable. Ensure the pipe strap is under the heating cable.
Loop and tape extra heating cable to the pipe. Minimum bend radius is ¾ in (20 mm).
CAUTION: To avoid pinching the heating cable, be sure the cable is not under the pipe strap.
AVERTISSEMENT : Pour éviter de pincer le câble chauffant, assurez-vous que le câble ne se trouve pas sous la sangle du tuyau.

Diagram showing securing the end seal stand to the pipe with a strap and looping excess cable.

Step 12A: Using Pipe Adapter for Small Pipes

Note: For 1-in (25-mm) and smaller pipes, use the adapter (purchased separately) between the stand and the pipe. Position the adapter with the side shown facing up.

Diagram showing the use of a pipe adapter for smaller pipes.

Step 13: Crimp Connections

Place blue crimps onto the bus wires.
Crimp bus wires to lead wires.

Diagram showing placing and crimping the insulated parallel crimps onto the bus wires.

Step 14: Light Assembly

Push excess wire inside the light. Be sure wires are not caught in threads.
Tighten the light onto the end seal stand. Torque = 22 ± 2 Nm.

Diagram showing pushing excess wire into the light and tightening the light onto the stand.

Step 15: Cable Tie Application

Insert the cable tie through the slot on the stand and the slot on the light, then tighten.

Diagram showing inserting and tightening the cable tie.

Step 16: Final Sealing and Labeling

Apply insulation and weather-seal the stand entry.
Fasten the end seal label to the insulation.
Leave these instructions with the end user for future reference.

Diagram showing applying weather seal and the end seal label.

Troubleshooting Guide

Problem: Light is dim or off.

Troubleshooting steps:

Check that the light voltage rating matches the supply voltage for the heat-tracing circuit. Supply voltage lower or higher than the light rating will cause malfunctions.
Check that the heat-tracing circuit is energized. Although the circuit breaker is on, control devices such as thermostats may switch the heating cable off.
Following electrical safety procedures, disconnect the supply voltage, unscrew the light from the end seal base, and check that the crimp connections to the heating cable bus wires are tight and not crossed or shorted. Loose connections or shorts will cause malfunctions.
With the circuit off, attach volt meter leads to the crimps. Energize the circuit and measure the voltage at the light. Use the following table to determine whether the voltage measured is within the acceptable range.

If voltage at the light is in the acceptable range and connections are good, the light may be defective or damaged. Replace the light.

If there is no voltage at the light, there may be breaks in the heating cable between the power connection and the end seal. Check for splice or tee connections that may be left open.

If voltage at the light is above specified limits, the light may be off. Voltages above the specified range can damage the light. Replace the light with the correct version for the line supply voltage or adjust the supply voltage accordingly.

If voltage at the light is present but below specified limits, the light may be dim or off. The following table lists typical causes for low voltages and possible solutions.

Cause	Solution
Supply voltage at the start of the circuit is low (light is designed to work with supply voltages within 10% of nominal).	Increase power wire gauge size to reduce voltage drop between the panel and the heating cable power connection.
Heating cable length is too long (light is designed to work with published maximum circuit lengths).	Split the heating cable into multiple circuits. Shorten the length of the heating cable.
Heating cable is started under very cold conditions (heating-cable voltage drop is very high for the first minutes of a very cold start-up).	Wait for the heating cable to warm up. Voltage at the light will increase.
Heating cable controller is reducing voltage (light may not work with controllers that phase fire to reduce line voltage).	Turn off the phase firing function in the heating cable controller.

Problem: Cap cannot be tightened completely.