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 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
2 Certications / Approvals� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
3 Technical data � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
4 Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
5 Kit contents � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
6 Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Required tools / equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cautions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Preparation of trace heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trace heater to trace heater connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Troubleshooting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Cold lead cable to trace heater connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation of the end seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 Troubleshooting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25
9 Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26
10 Sécurité et advertissements � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 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 xed 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
bus wire
heating matrix
insulation jacket
The following terms describe the parts of the trace heater
within these instructions:
grounding braid
outer jacket
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Installation Instruction
Cable to cable Splice - Heat shrink technology connection system
2 Certications / 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
Operation temperature range -67 to +185 °F / -55 to +85° C
Min. installation temperature -4 °F / -20 °C
Max. circuit load 24 A
Ingress protection NEMA Type 4X
Protection classication N/A - for use in ordinary locations only!
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Installation Instruction
4 Safety
Cable to cable Splice - Heat shrink technology connection system
Safety
For safe installation and operation of the cold applied
connection system the technical requirements and
instructions given in this manual must be followed.
WARNING
Risk of re 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 specied 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.
Sécurité
An 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.
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 chauant contient des informations importantes
additionalles qu’il convient de respecter en plus du
present manuel.
• La pose du système de connexion et des câbles
chauants doit être réalisée avec le plus grand soin.
• Utilisez le câble chauant et le système de
connexion adaptés à l’usage prévu et répondant aux
caractéristiques de fonctionnement spéciées à la
section Caractéristiques techniques.
• Le rayon de courbure du câble chauant ne doit pas
être inférieur à 1” (25 mm).Ne pas courber le câble
chauant 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 chauant.
• Conservez tous les éléments et les câbles chauants
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 nal.
• 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:
No. Component Qty. Designation Dimensions
Bus wire splice lug
Heat shrink technology
connection system for
Danfoss PX / RX trace heaters
1 3 x
2 4 x Ferrule -
3 4 x
4 2 x
5 1 x
6 1 x
7 1 x
8 1 x
9 1 x
10 2 x
with heat shrink
tube
Heat shrink tube for
bus wires
Outer heat shrink
tube for bus wires
Connection covering
heat shrink tube
Final covering heat
shrink tube
Outer protection
heat shrink tube
Heat shrink tube for
end-termination
Outer heat shrink
tube for end-termi-
nation
Protection heat
shrink tube for
end-termination
-
Length:
1 3/8" / 35 mm
Diameter:
3/16” / 4,8 mm
Length:
3/4” / 19 mm
Diameter:
3/8” / 9,5 mm
Length:
4 1/2” / 115 mm
Diameter:
1/2” / 12 mm
Length:
7” / 175 mm
Diameter:
3/4” / 19 mm
Length:
8" / 200 mm
Diameter
3/4" / 19 mm
Length:
3/4” / 19 mm
Diameter:
1/2” / 12 mm
Length:
3 1/8" / 80 mm
Diameter:
3/4” / 19 mm
Length:
2 3/8” / 60 mm
Diameter:
3/4” / 19 mm
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Installation Instruction
6 Installation
Cable to cable Splice - Heat shrink technology connection system
Required tools / equipment
The following tools and equipment are required for installation of the connection system:
• Wire cutters
• Flat screwdriver
• Crimping pliers 97 52 37 KNIPEX or equivalent
• Square-crimp crimping pliers
• Tape measure
• Utility knife
• Needle-nose pliers (2x)
• Heat gun
2 x
Cautions and warnings
WARNING:
Risk of re 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.
1
2
• 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.
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Installation Instruction
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.
Cable to cable Splice - Heat shrink technology connection system
Unroll the required trace heater in a straight line and cut to the cor-rect length. Cut o the trace
heater ensuring a straight cut.
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.
Carefully separate the strands of the grounding braid of the insulation jacket.
Twist the grounding braid in order to form a pigtail.
3
4
5
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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.
6
7
8
Pull o the bus wires while holding the heating matrix.
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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.
10
11
Cut in a triangle (¼” (5 mm)) between the bus wires.
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