Thermon Terminator™ ZT-R-XP & ZT-C-R-XP Thermostat Connection Kit Installation Procedures

Dimensions

The Terminator ZT-R-XP and ZT-C-R-XP units have the following approximate dimensions: Height: 260 mm, Width: 155 mm, Depth: 190 mm, Base Diameter: 100 mm.

Receiving, Storing and Handling

1. Inspect materials for damage incurred during shipping.
2. Report damages to the carrier for settlement.
3. Identify parts against the packing list to ensure the proper type and quantity has been received.
4. Store in a dry location.

Kit Contents

Note: Junction Box Lid and Junction Box Cord are also included but not explicitly numbered in the diagram.

Thermostat Type Terminals:

• ZT-C-230 Vac: 4 mm² terminals
• ZT-C-400 Vac: 6 mm² terminals

Tools Required

• 3 mm tool
• 8 mm tool
• Terminator-LN-Tool (order separately)
• 28 mm tool

Warnings

• Due to the risk of electrical shock, arcing, and fire caused by product damage or improper usage, installation, or maintenance, a ground-fault protection device is required.
• Installation must comply with Thermon requirements (including form PN 50273U for Ex systems) and be installed in accordance with regulations as per EN IEC 60079-14 for hazardous areas (where applicable), or any other applicable national and local codes.
• Component approvals and performance ratings are based on the use of Thermon specified parts only.
• De-energize all power sources before opening the enclosure.
• Avoid electrostatic charge. Clean only with a damp cloth.
• Keep ends of heating cable and kit components dry before and during installation.
• Minimum bending radius of heating cable is 6 times the cable outer diameter.
• Individuals installing these products are responsible for complying with all applicable safety and health guidelines. Proper Personal Protective Equipment (PPE) should be utilized during installation. Contact Thermon if you have any additional questions.

Certifications/Approvals

General: IP66; -60°C ≤ Ta ≤ +55°C T6, 85°C 16 Amps Max; -60°C ≤ Ta ≤ +50°C T5, 100°C 25 Amps Max. For Ordinary & Hazardous Locations.

Terminator ZT: IEC IECEX FMG 10.0022X Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C; CE 2809 Ex II 2 GD Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C FM10ATEX0058X

Terminator ZT-C: IEC IECEX EPS 19.0094X Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C; CE 2809 Ex II 2 GD Ex db eb IIC T5-T6, Ex tb IIIC T100°C-T85°C EPS 19ATEX1216X

Installation Procedures

Step 1: Prepare the Heating Cable

Cut the end of the heating cable at an angle to help pierce the grommet. Leave additional cable length to accommodate an expansion loop. Ensure the cut is clean and precise.

[Diagram Description: Shows a heating cable being cut at an angle with wire cutters. Dimensions indicate a minimum of 380 mm (15 inches) from the pipe and 100 mm (4 inches) from the cut end to the expediter.]

Step 2: Insert Cable into Expediter

Insert the prepared heating cable into the expediter assembly. If the expediter is mounted on the bottom or side of the pipe, punch out the designated weep hole in the expediter to allow moisture to escape.

[Diagram Description: Shows the heating cable being inserted into the expediter. A close-up highlights the weep hole punch-out option.]

Step 3: Route Cable Through Support Base

Slide the expediter assembly towards the pipe and route the heating cable through the support base entry point.

[Diagram Description: Illustrates the expediter being slid along the cable and routed through the support base.]

Step 4: Temporarily Mount Expediter

Temporarily secure the expediter to the pipe using a pipe band. Ensure the pipe band does not overlap or constrict the heating cable itself.

[Diagram Description: Shows the expediter attached to the pipe with a pipe band. A close-up indicates the correct placement of the band, avoiding the cable.]

Step 5: Cut Cable End

Cut off the end of the heating cable. Ensure the cut is clean and perpendicular to the cable length.

[Diagram Description: Shows the end of the heating cable being cut cleanly.]

Step 6: Terminate Cable

Terminate the heating cable using the appropriate PETK termination kit. Refer to the specific installation instructions provided with the PETK kit for detailed guidance on wire stripping and termination.

[Diagram Description: Depicts the heating cable being terminated with a PETK kit, showing wires being connected.]

Step 7: Remove Expediter

Remove the expediter from the pipe by detaching the pipe band that was used for temporary mounting.

[Diagram Description: Shows the pipe band being removed to detach the expediter.]

Step 8: Route Thermostat Bulb

Route the thermostat bulb through the nut and the opening in the junction box base. If necessary, apply a user-supplied lubricant to the end of the thermostat bulb to ease insertion. Slide the bulb through the conical grommet hole. Push any excess capillary tube through the expediter.

[Diagram Description: Illustrates the thermostat bulb being guided through the junction box base opening and grommet. A close-up shows the capillary tube being pushed through the expediter.]

Step 9: Insert Banding Guide

Insert the banding guide into its designated slot and snap it securely into place.

[Diagram Description: Shows the banding guide being inserted and snapped into the expediter assembly.]

Step 10: Mount Expediter to Pipe

Mount the expediter assembly to the pipe using a pipe band. Again, ensure the pipe band does not constrict the heating cable. If necessary, temporarily mount the junction box base onto the expediter for stability during this step.

[Diagram Description: Shows the expediter being banded to the pipe, with the junction box base potentially attached temporarily.]

Step 11: Manage Excess Cable and Tube

Push any excess heating cable and capillary tube back through the expediter. Tighten the cap securely. Tape the cable expansion loop to the pipe to prevent movement.

[Diagram Description: Depicts excess cable and tube being pushed back, the cap being tightened, and the expansion loop taped to the pipe.]

Step 12: Secure Thermostat Bulb and Tube

Fix the thermostat bulb and its capillary tube to the pipe, ensuring they are positioned correctly and secured.

[Diagram Description: Shows the thermostat bulb and capillary tube being attached and secured to the pipe.]

Step 13: Mount Junction Box Base

Take out the thermostat. Mount the junction box base onto the expediter. Ensure the slots are aligned to properly orient the junction box base. Tighten the nut using the Terminator-LN-Tool. If mounting horizontally, ensure the threaded gland holes face downward.

[Diagram Description: Shows the junction box base being mounted onto the expediter, with emphasis on slot alignment and tightening the nut. A note about horizontal mounting orientation is included.]

Step 14: Install Glands and Plugs

Remove the M25 dust cap. Install the M25 power gland (ordered separately) and an M25 blind plug. For in-line splices, T-splices, or end terminations, install an additional M25 blind plug (order M25-B-EXE separately) instead of the M25 power gland.

[Diagram Description: Shows the M25 dust cap being removed and replaced with a power gland and blind plug. Options for different termination types are indicated.]

Step 15: Install Power Cable

Install the power cable into the appropriate gland.

[Diagram Description: Illustrates the power cable being connected to the junction box via the gland.]

Step 16: Wire and Set Thermostat

Install the thermostat and complete the system wiring. Terminal set screws should be tightened to a torque value of 1.4 Nm (12.4 lb-in). Refer to the wiring details section for proper connections. Set the thermostat to the desired setpoint.

[Diagram Description: Shows the thermostat being installed and wired. A close-up indicates terminal set screw tightening and torque value. A note about setting the desired setpoint is present.]

Step 17: Install Junction Box Lid

Install the junction box lid and twist it hand-tight. Insert a screwdriver into the ratchet slots located on the side of the junction box base.

[Diagram Description: Shows the junction box lid being placed and hand-tightened. A screwdriver is shown engaging with the ratchet slots.]

Step 18: Secure Junction Box Lid

Use the screwdriver to ratchet the junction box lid. The lid will rotate approximately 30 degrees to secure it.

[Diagram Description: Illustrates the screwdriver being used to rotate the lid via the ratchet mechanism, showing the 30-degree rotation.]

Step 19: Verify Lid Latch

Confirm that the lid latch mechanism is fully engaged. To remove the lid, repeat steps 17 and 18 in the reverse direction.

[Diagram Description: Shows the lid latch mechanism in its fully engaged state. Instructions for lid removal are provided.]

Wiring Details

The following diagrams illustrate the wiring connections for the Terminator thermostat kits.

Single Conductor Wiring (Heat Trace)

Heat Trace #1: Connect to Terminal L1.

Heat Trace #2: Connect to Terminal N.

Ground (PE): Connect to Terminal PE.

Thermostat Connection (2 Heating Cables)

This configuration shows connections for two heating cables. The thermostat bulb is routed through the junction box and connected to the heating circuit.

Power Supply

Line (L1): Connect to the power supply line.

Neutral (N): Connect to the power supply neutral.

Protective Earth (PE): Connect to the power supply ground.

[Diagram Description: The wiring diagram shows three main sections: Single Conductor (Heat Trace #1, Heat Trace #2, PE), Power Supply (L1, N, PE), and Thermostat Connection (2 Heating Cables) with connections to L1, N, and PE terminals within the thermostat unit.]