Danfoss Cable to cable Splice Installation guide
Installation Instruction
Cable to cable Splice
Heat shrink technology connection system
Installation Instruction Cable to cable Splice - Heat shrink technology connection system
Table of contents
1 |
Overview |
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2 |
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Certifications / Approvals |
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3 |
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Technical data |
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4 |
Safety |
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4 |
5 |
Kit contents |
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5 |
6 |
Installation |
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Required tools / equipment . . . . . . . . . . . . . . . . . . . . . . . |
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6 |
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Cautions and warnings . |
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6 |
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Preparation of trace heaters . . . . . . . . . . . . . . . . . . . . . . . |
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Trace heater to trace heater connection. . . . . . . . . . . . . . . . . . . |
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. 11 |
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Troubleshooting |
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Cold lead cable to trace heater connection. . . . . . . . . . . . . . . . . |
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Installation of the end seal. |
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22 |
8 |
Troubleshooting |
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25 |
9 |
Safety |
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26 |
10 |
Sécurité et advertissements |
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27 |
1 Overview
This manual introduces the installation and operation of Danfoss heat shrink splice technology. The connection is established using splice lugs and sealed with heat shrink tubes. Catalog No.: 088L0006.
The trace heating system uses a self-regulating trace heater. It features a temperature-dependent resistive heating element that regulates and limits the heat according to the ambient temperature. If the ambient temperature rises, the power output of the trace heater is reduced. This self-regulating property prevents overheating which would cause damage to the trace heater. Even crossing or overlapping with other trace heaters (or other portions of the same trace heater) are possible.
The heating system is set up as a fixed equipment heating system for pipes in ordinary areas. Thanks to the parallel design the trace heater can be cut and installed to any required length (mind the maximum heating circuit length according to system’s design guide).
It is suitable for the following self-regulating trace heaters:
•Danfoss PX Pipe Trace Heating System
•Danfoss RX-C Roof and Gutter De-Icing System
The following terms describe the parts of the trace heater within these instructions:
bus wire heating matrix insulation jacket
grounding braid
outer jacket
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
2 Certifications / Approvals
Heat shrink technology connection system for Danfoss PX/RX trace heaters.
3 Technical data
Ambient temperature range |
-67 |
to +185 °F / -55 to +85° C |
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Operation temperature range |
-67 |
to +185 °F / -55 to +85° C |
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Min. installation temperature |
-4 °F / -20 °C |
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Max. circuit load |
24 A |
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Ingress protection |
NEMA Type 4X |
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Protection classification |
N/A - for use in ordinary locations only! |
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
4 Safety
Safety |
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Sécurité |
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For safe installation and operation of the cold applied connection system the technical requirements and instructions given in this manual must be followed.
Afin de garantir la sécurité lors de l’installation et de l’utilisation du système de connexion à liaison froide, il est impératif de respecter les exigences ainsi que les consignes techniques mentionnées dans le présent manuel.
WARNING
Risk of fire or electrical shock. Follow these guidelines to avoid personal injury or material damage.
•All electrical systems and installations must comply with Danfoss requirements and be installed in accordance with the relevant electrical codes and any other applicable national and local codes.
•The US and Canadian electrical codes require ground fault protection to be provided for all trace heating circuits.
•Install the connection system and trace heaters carefully.
•Use the trace heater and connection system in accordance with the intended purpose and strictly comply with the operational data specified in section Technical Data.
•The bending radius of the trace heater must be at least 1” (25 mm).Do not bend on the narrow axis.
•Any defective component of the kit must be replaced before installation.
•To avoid short circuits, do not connect the trace heater bus wires together.
•Keep all components and the trace heaters dry before and during installation.
•Beware of hot surfaces when using the heat gun.
•Keep these instructions for future reference.If applicable, leave them with the end user.
•De-energize before installation or servicing.
•Use only original accessories.
NOTICE
The following instructions are provided in English only. Refer to www.danfoss.com for the French version.
AVERTISSEMENT
Risque d’incendie ou d’électrocution. Suivez ces consignes pour éviter toute blessure ou dommage matériel.
•Tous les systèmes et installations électriques doivent satisfaire aux exigences imposées par la société Danfoss et doivent être installés conformément aux normes électriques en vigueur ainsi qu’aux autres prescriptions nationales et locales applicables.
•Les normes électriques américaines et canadiennes imposent une protection contre les défauts à la terre pour tous les circuits de traçage électrique.
•Notez que le guide de conception fourni avec chaque cable chauffant contient des informations importantes additionalles qu’il convient de respecter en plus du present manuel.
•La pose du système de connexion et des câbles chauffants doit être réalisée avec le plus grand soin.
•Utilisez le câble chauffant et le système de connexion adaptés à l’usage prévu et répondant aux caractéristiques de fonctionnement spécifiées à la section Caractéristiques techniques.
•Le rayon de courbure du câble chauffant ne doit pas être inférieur à 1” (25 mm).Ne pas courber le câble chauffant sur la tranche.
•Tout élément défectueux dans le kit doit être remplacé avant l’installation.
•Pour éviter un court-circuit, ne jamais raccorder ensemble les deux conducteurs du câble chauffant.
•Conservez tous les éléments et les câbles chauffants au sec avant et pendant l’installation.
•Soyez prudent lors de l’utilisation du pistolet à air chaud, certaines surfaces peuvent devenir brûlantes.
•Conservez ces instructions pour un usage ultérieur.Le cas échéant, remettez-les à l’utilisateur final.
•Mettre hors tension avant toute installation ou opération de maintenance.
•Utilisez exclusivement des pièces et accessoires d’origine.
AVIS
Les instructions qui suivent sont fournies en anglais uniquement. Veuillez vous référer au site www.danfoss.com pour la version française.
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
5 Kit contents
The following table lists the kit contents for the Danfoss heat shrink technology connection system:
Heat shrink technology connection system for Danfoss PX / RX trace heaters
No. |
Component |
Qty. |
Designation |
Dimensions |
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Bus wire splice lug |
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1 |
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3 x |
with heat shrink |
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tube |
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2 |
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4 x |
Ferrule |
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Length: |
3 |
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4 x |
Heat shrink tube for |
1 3/8" / 35 mm |
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bus wires |
Diameter: |
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3/16” / 4,8 mm |
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Length: |
4 |
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2 x |
Outer heat shrink |
3/4” / 19 mm |
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tube for bus wires |
Diameter: |
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3/8” / 9,5 mm |
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Length: |
5 |
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1 x |
Connection covering |
4 1/2” / 115 mm |
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heat shrink tube |
Diameter: |
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1/2” / 12 mm |
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Length: |
6 |
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1 x |
Final covering heat |
7” / 175 mm |
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shrink tube |
Diameter: |
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3/4” / 19 mm |
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Length: |
7 |
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1 x |
Outer protection |
8" / 200 mm |
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heat shrink tube |
Diameter |
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3/4" / 19 mm |
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Length: |
8 |
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1 x |
Heat shrink tube for |
3/4” / 19 mm |
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end-termination |
Diameter: |
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1/2” / 12 mm |
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Outer heat shrink |
Length: |
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3 1/8" / 80 mm |
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1 x |
tube for end-termi- |
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Diameter: |
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nation |
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3/4” / 19 mm |
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Protection heat |
Length: |
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2 3/8” / 60 mm |
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10 |
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2 x |
shrink tube for |
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Diameter: |
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end-termination |
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3/4” / 19 mm |
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© Danfoss | 2022.02 | 5 |
Installation Instruction Cable to cable Splice - Heat shrink technology connection system
6 Installation
Required tools / equipment |
1 |
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The following tools and equipment are required for installation of the connection system:
• Wire cutters |
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• Flat screwdriver |
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• Crimping pliers 97 52 37 KNIPEX or equivalent |
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• Square-crimp crimping pliers |
2 x |
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•Tape measure
•Utility knife
• Needle-nose pliers (2x)
• Heat gun
Cautions and warnings |
2 |
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WARNING: |
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Risk of fire or electrical shock. De-energize all power circuits before installation or servicing. Always use ground fault equip-ment protection with the heat tracing system.
•Double-check that all power circuits are de-energized before you begin your work.
•Make sure that you do not exceed the maximum heating circuit length for the trace heater type you use. Refer to the design guide of the heating system.
6 | © Danfoss | 2022.02 |
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
Preparation of trace heaters
WARNING:
Risk of short cuts and/or material damage. Keep the trace heater ends dry before and during installation. Observe the design guide of the trace heating system.
Unroll the required trace heater in a straight line and cut to the cor-rect length. Cut off the trace |
3 |
heater ensuring a straight cut. |
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Do not bend or pinch the trace heater, or pull it over sharp edges.
Remove 2 3/8" (60 mm) of the outer jacket on the end of the trace heater. |
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Carefully separate the strands of the grounding braid of the insulation jacket. |
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Twist the grounding braid in order to form a pigtail. |
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
Remove 1 1/2" (40 mm) of the insulating jacket.
Make a small cut over and under each bus wire. Take care not to damage the bus wires.
Carefully make an incision into the edges of the heating matrix. Take care not to damage the bus wires.
Pull off the bus wires while holding the heating matrix.
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8
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Installation Instruction Cable to cable Splice - Heat shrink technology connection system
Remove any heating matrix that sticks to the bus wires.
Twist the bus wires.
Remove the remaining heating matrix. Take care not to damage the bus wires.
Cut in a triangle (¼” (5 mm)) between the bus wires.
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