Installation Instruction
Power connection kit
Cable to Junction Box with ½” NPT cable gland
Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
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 the trace heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of the heat shrink tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation of the end seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Troubleshooting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
8 Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
9 Sécurité et advertissements� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19
1 Overview
Cold applied connection system for use with a ½” NPT thread junction box Danfoss PX or
RX trace heaters.
Catalog No.: 088L0023.
This manual introduces the operation and installation of Danfoss heat shrink connection technology
for use with a ½” NPT thread junction box and the following self-regulating trace heaters:
• Danfoss PX Pipe Trace Heating System
• Danfoss RX-C Roof and Gutter De-Icing System
To connect the trace heater to the cold lead cable the 2 bus wires are insulated with heat shrink tubes,
then connected to the cold lead cable inside the junction box. Additionally, a green/yellow heat shrink
tube is provided to connect the twisted grounding braid to the grounding conductor. Finally, the end
of the trace heater is insulated by means of another heat shrink tube.
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
Power connection kit - Cable to Junction Box with ½” NPT cable gland
2 Certications / Approvals
Heat shrink technology connection system for use with a ½” NPT thread junction box and
Danfoss PX/RX trace heaters
3 Technical data
Ambient temperature range -40 °F to +185 °F /
-40 °C to +85° C
Max. operating temperature end cap 185 °F / 85 °C
Electrical data see specications of the trace heater used
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Installation Instruction
4 Safety
Power connection kit - Cable to Junction Box with ½” NPT cable gland
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
Power connection kit - Cable to Junction Box with ½” NPT cable gland
5 Kit contents
The following table lists the kit contents for each of the heat shrink technology connection systems for
PX/RX trace heaters:
Power connection kit
2 x Heat shrink tube for bus wires (black) 1 x Heat shrink tube for grounding braid
(green/yellow)
1 x Outer heat shrink tube for bus wires (black) 3 x Terminal block
1 x Plastic gland body 1 x Inner heat shrink tube for end-termination
1 x Grommet 1 x Outer heat shrink tube for end-termination
1 x Fixing nut 2 x Protection heat shrink end termination
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Installation Instruction
6 Installation
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Required tools / equipment
The following tools and equipment are required for installation of the connection system:
• Wire cutters
• Flat screwdriver
• Heat gun
• Utility knife
• Needle-nose pliers (2x)
• Tape measure
• 4” x 4” (or larger) UL Listed or CSA Certied junction box
with ½” NPT thread.
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 equipment within 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 system manual of the heating system
1
2
Advertissement:
Risque d’incendie ou d’electrocution. Mettre tous les circuits électriques hors tension avant toute
installation ou opération de maintenance. Toujours utiliser un dispositif de protection contre les
défauts à la terre au sein du système de traçage électrique.
• Vériez bien que tous les circuits électriques sont hors tension avant de débuter
votre travail.
• Veillez à ne pas dépasser la longueur de circuit de traçage maximale autorisée pour
le type de câble chauant utilisé. Consultez à ce sujet le guide de conception du
systéme de traçage.
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Preparation of the trace heater
WARNING:
Risk of short cuts and material damage. Keep the trace heater ends dry before and during installation.
Observe the trace heater’s installation instructions.
Unroll the required trace heater in a straight line and cut to the correct length. Cut o the trace heater
ensuring a straight cut:
WARNING:
Risk of electrical shock and material damage. The gland body and grommet for PX/RX trace heaters
are slightly dierent. Make sure to use the cable gland kit that ts the trace heater you use.
ADVERTISSEMENT:
Risque d’électrocution et/ou de dommages matériels. Le corps du presse-étoupe et le passe-l
destinés aux câbles chauants PX/RX sont légèrement diérents. Prenez donc garde á bien utiliser
le corps du presse-étoupe et le passe-l adaptés au cäble chauant utilisé.
Slide the xing nut, the grommet and the gland body onto the trace heater.
3
4
Remove 5 ¾” (145 mm) of the outer jacket on the end of the trace heater.
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Push the grounding braid back. Use the screwdriver to form an eyelet. Be careful not to damage the
internal insulation jacket
Bend the trace heater and pull the heating matrix out of the grounding braid.
Twist the grounding braid in order to form a wire.
6
7
8
Push the green/yellow heat shrink tube (length: 4 ¾” (120 mm); diameter: ¼” (6 mm) onto the
twisted grounding braid.
Shrink the tube at a temperature of 275 °F / 135 °C.
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Remove 4 ½” (115 mm) of the internal insulation 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.
10
11
Pull o the bus wires while holding the heating matrix.
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Installation Instruction
:
NOTICE
Risk of malfunction of the heating system. Before you continue, make sure that the bus wires are
intact and not nicked or damaged.
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Remove any remaining 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.
13
14
Carefully cut in a triangle (⁄” (5 mm)) between the bus wires. Take care not to damage the bus
wires.
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Installation of the heat shrink tubes
Slide the bus wire heat shrink tubes (length: 4” (100 mm); diameter: ¼” (6 mm)) onto the bus
wires.
WARNING:
Risk of burns. Beware of hot surfaces when using the heat gun.
ADVERTISSEMENT:
Risque de brülure. Soyez prudent lors de l’utilisation du pistolet á ait chaud, certaines surfaces
peuvent devenir brülantes.
Shrink the tubes at a temperature of 275 °F / 135 °C.
16
Push the outer heat shrink tube (length: 1” (25 mm); diameter: ½” (12 mm)) over the end of the
trace heater.
Shrink the tube at a temperature of 275 °F / 135 °C.
While still hot, compress the tube between the bus wires using pliers and hold for 5 seconds.
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Installation Instruction
Cable connection
Feed the cables into the junction box and tighten the gland to a torque of 6 ft. lbs.
For powered splice and powered T connection kits repeat steps 3 to 16 to prepare the remaining trace
heaters, introduce them into the junction box and tighten the gland.
Power connection kit - Cable to Junction Box with ½” NPT cable gland
18
↻ 6 ft. lbs.
Feed the cold lead cable into the junction box.
Power connection
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Inside the junction box, use the individual terminal blocks to connect the bus wires and the
twisted grounding braid / grounding conductor to each other. Make sure that the wires are fully
engaged in the terminal block.
Line Neutral Ground
Establish all connections as shown in the following gure.
Power connection
20
21
Mount the cover of the junction box according to the manufacturer’s installation instructions.
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Installation of the end seal
Cut the trace heater o straight.
Remove 1 ¼” (30 mm) of the outer jacket on the trace heater.
Remove the exposed grounding braid. Make sure that the insulation jacket is not damaged.
Cut in a triangle (⅜” (5 mm)) between the bus wires.
23
24
25
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Put the inner heat shrink tube for the end-termination (length: ¾” (20 mm); diameter:
½” (12 mm)) over the end of the trace heater.
Leave an overlap of ⅝” (15 mm) .
Beginning at the end of the cable, shrink the tube at a temperature of 275 °F / 135 °C.
While still hot, compress the end of the tube using pliers and hold for 5 seconds.
Now, put the outer heat shrink tube (length: 2 ¾” (70 mm); diameter: ¾” (19 mm)) over the
end of the trace heater.
Make sure that it overlaps the bared part of the trace heater for ¾” (20 mm).
Beginning at the end of the cable, shrink the tube at a temperature of 275 °F / 135 °C.
26
27
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
Now, put the rst protection heat shrink tube (length: 2 ⅓” (60 mm); diameter: ¾” (19 mm) over
the end of the trace heater.
Leave a gap to the outer heat shrink tube of ¾” (20 mm).
Beginning at the end of the trace heater, shrink the tube at a temperature of 275 °F / 135 °C.
Fold over the overlapping end of the heat shrink tube ⅜” (10 mm).
Slightly press the end using pliers.
Now, put the second protection heat shrink tube
(length: 2 ⅓” (60 mm); diameter: ¾” (19mm)) over the end of the trace heater.
Leave a gap to the very rst heat shrink tube of ⅜” (10 mm).
Beginning at the end of the trace heater, shrink the tube at a temperature of 275 °F / 135 °C.
28
29
30
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
7 Troubleshooting
Problem Possible cause Remedy
Trace heater remains cold No power supply
Trace heater or cold lead cable not
properly connected
Control unit adjusted incorrectly
Automatic circuit breaker
disengages
Automatic circuit breaker
defective
Automatic circuit breaker has
wrong tripping characteristics,
e. g. “B” instead of “C”
Nominal circuit breaker size is
insucient
Maximum heating circuit length
has been exceeded
End seal has not been installed|
Short circuit
Humidity inside the connection
system or end seal
Ground fault protection
Trace heater damaged
is disengaged
Moisture in the junction box
Ground fault protection defective
Check the supply line
Connect the trace heater and
cold lead cable according to the
installation instructions
Adjust the control unit according
to the installation instructions
Replace the automatic circuit
breaker
Install an automatic circuit
breaker with Type-C tripping
characteristics
Install an automatic circuit breaker
with higher capacity (Observe
the maximum amperage of all
components of the trace heating
circuit!)
Split the heating circuit into
separate circuits
Install the end seal according to
the installation instructions
Identify the cause and remedy the
fault (e. g. ensure that tape tails are
not twisted)
Replace the connection system /
end seal
Replace the trace heater at the
point where it is damaged
Dry the junction box.
Be sure that the conduit drain is
installed and breathing properly
Replace the ground fault
protection device(s)
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Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
8 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.
• Note that the design guide that comes with each trace heater contains further important information and must be
followed in addition to this manual.
• 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.
Preparation of the trace heater
WARNING
Risk of re or electrical shock.De-energize all power circuits before installation or servicing. Always use ground fault
equipment within 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 system manual of the heating system.
WARNING
Risk of electrical shock and material damage.The gland body and grommet for PX/RX trace heaters are slightly dierent.
Make sure to use the cable gland kit that ts the trace heater you use.
WARNING
Risk of burns.Beware of hot surfaces when using the heat gun.
© Danfoss | 2021.11 | 18088L0023 & AN295968639331en-US0102
Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
9 Sécurité et advertissements
An de garantir la sécurité lors de l’installation et de l’utilisation du système de connexion par tech nique de
thermorétraction Danfoss, il est impératif de respecter les exigences techniques ainsi que les consignes 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 socié té 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.
• 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.
• Le câble de liaison froide doit être conforme aux exigences locales et être constitué de ls AWG 16 au minimum.
• Soyez prudent lors de l’utilisation du pistolet à air chaud, certaines surfaces peuvent devenir brû lantes.
• Chaque circuit chauant doit être clairement identié par un moyen permanent mentionnant le nom du fabricant, le
type de circuit, sa puissance et sa tension.
• N’employez jamais de ruban adhésif en vinyle, même en complément de ce kit.
• 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 Danfoss.
Avertissements et mises en garde
AVERTISSEMENT
Risque d’incendie ou de choc électrique. Éteignez tous les circuits d’alimentation avant l’installation ou l’entretien. Toujours
utiliser un équipement de défaut à la terre dans le système de traçage thermique.
• Vériez bien que tous les circuits électriques sont hors tension avant de débuter votre travail.
• Veillez à ne pas dépasser la longueur de circuit de traçage maximale autorisée pour le type de câble
chauant utilisé. Consultez à ce sujet le guide de conception du système de traçage.
AVERTISSEMENT
Risque d’électrocution et/ou de dommages matériels.Le corps du presse-étoupe et le passe-l destinés aux câbles
chauants PX/RX sont légèrement diérents.Prenez donc garde á bien utiliser le corps du presse-étoupe et le passe-l
adaptés au cäble chauant utilisé.
AVERTISSEMENT
Risque de brülure.Soyez prudent lors de l’utilisation du pistolet á ait chaud, certaines surfaces peuvent devenir brülantes.
19 | © Danfoss | 2021.11
088L0023 & AN295968639331en-US0102
Installation Instruction
Power connection kit - Cable to Junction Box with ½” NPT cable gland
© Danfoss | 2021.11 | 20088L0023 & AN295968639331en-US0102
Danfoss
11655 Crossroads Circle
Baltimore, MD 21220 USA
Phone: 1-888-DANFOSS (326-3677)
Fax: 416 -352-5981
lx.danfoss.com
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