EasyHeat EasyHeat SKDG Cable Repair Kit, Snow Melting Accessories, 14137-000 Instruction Sheet
SKDG Cable Repair Kit Instructions
DESCRIPTION
Having to repair your EasyHeat cable is an extremely rare occurrence.
Damage is almost always a function of field conditions, such as
impacts with tools.
The SKDG Cable Repair Kit is intended to be used to repair dual and
single conductor construction EasyHeat Snow Melting mats and cable
kits, thermal storage and radiant heating mats damaged either during
installation or subsequent operation.
KIT CONTENTS
5 Butt crimp connectors
9 Parallel crimp connectors (small)
5 Parallel crimp connectors (large)
2 Shrink tubes (small)
4 Shrink tubes (medium)
TOOLS REQUIRED
Side cutters
Crimping pliers
Coaxial cable strippers or/and utility knife
This kit contains all the materials needed to replace:
• For the single construction cable, two short—up to 2.5 cm
• For the dual construction cable, one short—up to 2.5 cm
Use of this kit may require up to 60 cm (24 in) of exposed cable.
2 Shrink tubes (large)
4 Fiberglass tapes
2 AWG 10 jumper wires (large diameter)
4 AWG 14 jumper wires (small diameter)
Heat gun
Ohmmeter
Insulation resistance tester (megohmmeter)
(1 in)—sections of damaged heating cable, or repair/replace
two heating cable-to-cold lead splices.
(1 in)—sections of damaged heating cable, or repair/replace
one heating cable-to-cold lead splices or repair/replace two tail
splices
WARNINGS!
• Shortening of the heater cable will result in the cable running hotter. Excessive shortening may result in a risk of personal
a
injury and/or re. DO NOT install more than two SKDG kits on any cable. Contact EasyHeat for additional information.
• Turn breaker off at the panel and tag the panel to ensure that no one turns the breaker on. Disconnect the heater wires from
the controller as an added safety step and to conduct testing during and after repairs.
• Determine location of fault before beginning any repair work.
• DO NOT use this kit to repair any sensor wire.
CAUTIONS
• Heat guns, if not handled carefully, can result in burns. Heat
shrink tubing and the sealant retain heat. Be careful in handling
them before they have cooled completely.
• Excessive heat can damage shrink tubing and cable materials.
Use care not to overheat materials. Damage from heat may not
be visible.
NOTICE: REPAIRING A DAMAGED CABLE WILL VOID THE ORIGINAL HEATING CABLE WARRANTY.
• No wires should protrude past the ends of the connectors.
Carefully trim wires flush as needed. Sharp wires and loose
wire strands can pierce through the heat shrink and may result
in shorting.
• Allow the inner heat shrink to cool before applying the outer heat
shrink. Failure to do this may leave the inner tube too soft and
result in damage as the outer tube is shrunk.
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
1
DIRECTIONS - HEATING CABLE TO HEATING CABLE SPLICE
Dual Conductor Construction
Sno*Melter mats and cable kits, thermal storage and radiant heating
Single Conductor Construction
Sno*Melter, thermal storage and radiant heating mats
mats
Text and pictures across both columns applies to single and dual construction.
Use small parallel crimp connectors for the conductor connection
Use small parallel crimp connectors
and parallel large crimp connectors for the ground connection
1. Carefully expose the damaged heating cable by removing any material (concrete, asphalt) in which the heating cable is embedded.
Remove the damaged section of the heating cable by cutting it off with sidecutters.
2. Carefully expose about 25 cm (10 in) of heating cable on either side of the damaged area by removing any material (concrete, asphalt)
covering the cable in this area.
3. Remove 9 cm (3.5 in) of outer jacket from each side of the heating cable. Be careful not to damage ground braid beneath the jacket.
4. Unbraid the ground braid back to the outer jacket and twist it to one side to form a pigtail on each cable.
9 cm (3.5 in)
5. Trim one of the paired conductors 2 cm (0.75 in) back, and
the braid 5 cm (2.0 in) back. Repeat this pattern on the other
cable. This allows the ground braid connection to be offset
from the primary conductor connections, which minimizes
both the size of the repaired area and the potential for the
ground connection to penetrate the primary connection.
5. Trim the primary conductor of one of the heating cables
13 mm (0.5 in) back from the braid pigtail, and trim the braid
pigtail on the other heating cable 13 mm (0.5 in) back from
the primary conductor on that cable connection. This allows
the ground braid connection to be offset from the primary
conductor connection, which minimizes both the size of the
repaired area and the potential for the ground connection to
penetrate the primary connection.
6.5 cm (2.5 in)
5 cm [2 in]
2 cm [0.75 in]
HEATING CABLE
6. Cut the small diameter jumper wire to the required length and
strip 6 mm (0.25 in) of insulation from the ends of each
primary conductor and the jumper wire (8 stripping in total).
6. Cut the small diameter jumper wire to the required length and
HEATING CABLE
6 mm
(0.25 in)
13 mm (0.5 in)
6.5 cm (2.5 in)
strip 6 mm (0.25 in) of insulation from the ends of each primary
conductor and the jumper wire (four stripping in total).
7. Cut the smaller diameter heat shrink to a 4.5 cm (1.75 in) length.
8. Slide the 4.5 cm (1.75 in) and one large (full length) shrink
tube over each portion of the cable. The medium shrink tube
may be shortened however, keep in mind at least 2.5 cm
(1 in) of overlap on each side of the splice and 2.5 cm (1 in)
in the middle is required for sealing purposes.
8. Slide the 4.5 cm (1.75 in) and one medium (full length) shrink
tube over each portion of the cable. The medium shrink tube
may be shortened however, keep in mind at least 2.5 cm (1 in)
of overlap on each side of the splice and 2.5 cm (1 in) in the
middle is required for sealing purposes.
9. Insert the conductor of each cable into the small connector and crimp securely to the jumper wire.
10. Center the
4.5 cm (1.75 in)
shrink tube over each connector, ensuring that all bare conductor/connector parts are under the shrink tube.
Starting at the center of the shrink tube, heat with heat gun until completely shrunk.
13 mm (0.5 in)
6 mm (0.25 in)
HEATING CABLE
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
2
DIRECTIONS - HEATING CABLE TO HEATING CABLE SPLICE (CONTINUED)
Jumper
Dual Conductor Construction
Sno*Melter mats and cable kits, thermal storage and radiant heating
Single Conductor Construction
Sno*Melter, thermal storage and radiant heating mats
mats
Text and pictures across both columns applies to single and dual construction.
Use small parallel crimp connectors for the conductor connection
Use small parallel crimp connectors
and parallel large crimp connectors for the ground connection
11. Wrap entire shrink tube areas with berglass tape.
Heat Shrink
(large)
Heating Cable
Small Connector
Wrap With Tape
Jumper Wire
Heat Shrink
(small)
Heating Cable
Heat Shrin
(large)
k
Heat Shrink
(large)
Heating Cable
12. Connect braids using AWG 14 jumper wire to extend ground braid and crimp securely.
13. Position large shrink tube over entire splice area and shrink
with heat gun. The shrink tubes must overlap at least 2.5 cm
(1 in) of overlap on each side of the splice and 2.5 cm
(1 in) in the middle for sealing purposes.
Connector
Overlap
Wires
13. Position medium shrink tube over entire splice area and shrink
with heat gun. The shrink tubes must overlap at least 2.5 cm
(1 in) of overlap on each side of the splice and 2.5 cm (1 in)
in the middle for sealing purposes.
Small Connector
Overlap
Wrap With Tape
Jumper Wire
Heat Shrink
(small)
Jumper
Wires
Connector
Heating Cable
Heat Shrink
(large)
Heat Shrink
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
3
DIRECTIONS - AWG 14 COLD LEAD TO HEATING CABLE SPLICE
OR COLD LEAD
Dual Conductor Construction
Sno*Melter mats and cable kits, thermal storage and radiant heating
Single Conductor Construction
Sno*Melter, thermal storage and radiant heating mats
mats
Text and pictures across both columns applies to single and dual construction.
Use small parallel crimp connectors for the conductor connection
Use small parallel crimp connectors
and parallel large crimp connectors for the ground connection
1. Carefully expose the original factory splice by removing any material (concrete, asphalt) in which the heating cable is embedded. Remove
the splice by cutting it off with sidecutters.
2. Carefully expose about 25 cm (10 in) of heating cable and about 25 cm (10 in) of cold lead by removing any material (concrete,
asphalt) covering it.
3. Remove 9 cm (3.5 in) of outer jacket from heating cable and cold lead. Be careful not to damage ground braid beneath the jacket.
4. Unbraid the ground braid back to the outer jacket and twist it to one side to form a pigtail on each cable (see Figure 5).
9 cm (3.5 in)
5. Trim the heating cables paired conductors 2 cm (0.75 in)
back, and the braid 5 cm (2 in) back. Repeat this pattern
on the cold lead. This allows the ground braid connection
to be offset from the primary conductor connections, which
minimizes both the size of the repaired area and the potential
for the ground connection to penetrate the primary connection.
5. Trim the primary conductor of the heating cable 1.5 cm (0.5
in) back from the braid pigtail, and trim the braid pigtail on the
cold lead 1.5 cm (0.5 in) back from the primary conductor
on the cold lead. This allows the ground braid connection
to be offset from the primary conductor connection, which
minimizes both the size of the repaired area and the potential
for the ground connection to penetrate the primary connection.
5 cm [2 in]
2 cm [0.75 in]
6.5 cm (2.5 in)
HEATING CABLE
HEATING CABLE
6 mm
(0.25 in)
13 mm (0.5 in)
13 mm (0.5 in)
6 mm (0.25 in)
COLD LEAD
6.5 cm (2.5 in)
6. Cut the small diameter jumper wire to the required length and strip 6
mm (0.25 in) of insulation from the ends of each primary conductor
and the jumper wire (8 stripping in total).
7. Cut the smaller diameter heat shrink to a
4.5 cm (1.75 in)
8. Slide the 4.5 cm (1.75 in) and one large (full length) shrink tube
over each portion of the cable. The medium shrink tube may be
shortened however, keep in mind at least 2.5 cm (1 in) of overlap
on each side of the splice and 2.5 cm (1 in) in the middle is
required for sealing purposes.
6. Cut the small diameter jumper wire to the required length
and strip 6 mm (0.25 in) of insulation from the ends of each
primary conductor and the jumper wire (four stripping in total).
length.
8. Slide the 4.5 cm (1.75 in) and one medium (full length) shrink
tube over each portion of the cable. The medium shrink tube may
be shortened however, keep in mind at least 2.5 cm (1 in) of
overlap on each side of the splice and 2.5 cm (1 in) in the middle
is required for sealing purposes.
9. Insert the conductor of each cable into the small connector and crimp securely to the jumper wire.
10. Center the 4.5 cm (1.75 in) shrink tube over each connector, ensuring that all bare conductor/connector parts are under the shrink
tube. Starting at the center of the shrink tube, heat with heat gun until completely shrunk.
11. Wrap entire shrink tube areas with berglass tape.
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
4
DIRECTIONS - AWG 14 COLD LEAD TO HEATING CABLE SPLICE (CONTINUED)
Jumper
Heat shrink
Heat shrink
Dual Conductor Construction
Sno*Melter mats and cable kits, thermal storage and radiant heating
Single Conductor Construction
Sno*Melter, thermal storage and radiant heating mats
mats
Text and pictures across both columns applies to single and dual construction.
Use small parallel crimp connectors for the conductor connection
Use small parallel crimp connectors
and parallel large crimp connectors for the ground connection
Heat Shrink
(large)
Heating Cable
Small Connector
Wrap With Tape
Jumper Wire
Heat Shrink
(small)
cold lead
Heat Shrin
(large)
k
Heat Shrink
(medium) (medium)
Heating Cable
12. Connect braids using AWG 14 jumper wire to extend ground braid and crimp securely.
13. Position large shrink tube over entire splice area and shrink
with heat gun. The shrink tubes must overlap at least
(1 in)
of overlap on each side of the splice and
2.5 cm
2.5 cm (1 in)
in the middle for sealing purposes.
Connector
Overlap
Wires
13. Position medium shrink tube over entire splice area and
shrink with heat gun. The shrink tubes must overlap at least
2.5 cm (1 in)
cm (1 in)
of overlap on each side of the splice and
in the middle for sealing purposes.
Small Connector
Overlap
Wrap With Tape
Jumper Wire
Heat Shrink
(small)
Jumper
Wires
Heat Shrink
cold lead
2.5
Connector
DIRECTIONS - AWG 10 COLD LEAD TO HEATING CABLE SPLICE
Dual Conductor Construction
Sno*Melter mats and cable kits, thermal storage and radiant heating
mats
Follow the same steps as for the AWG 14 cold lead to cable
splice directions. Use the larger diameter (AWG 10) jumper
wire and butt connectors for cold lead conductor to jumper wire
connection and large parallel crimp connector for jumper wire to
heating cable connection. Use smaller diameter (AWG 14) jumper
wire and parallel large crimp connectors for braid connections.
Heating cable
Parallel crimp
AWG 10
jumper wire
Butt crimp
AWG 10 cold lead
Single Conductor Construction
Sno*Melter, thermal storage and radiant heating mats
Follow the same steps as for the AWG 14 cold lead to cable splice
directions. Use the larger diameter (AWG 10) jumper wire and butt
connectors for conductor cold lead to jumper wire connection and
large parallel crimp connector for jumper wire to heating cable
connection. Use smaller diameter (AWG 14) jumper wire and parallel
small crimp connectors for braid connections.
Heating cable
Heat Shrink
AWG 10 jumper wire
AWG 10 cold lead
Butt crimp
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
5
HEATING CABLE TAIL SPLICE
HEATING CABLE
13 mm [0.5 in]
STRANDED
Dual Conductor Construction Only
For use with small crimp connectors
1. Carefully expose the original factory splice by removing
any mortar in which the splice is embedded. Remove the
damaged tail splice by cutting it off with side-cutters.
2. Carefully expose about 30 cm (12 in) of heating cable by
removing any mortar covering it.
3. Remove 4 cm (1.6 in) of outer jacket from heating cable
and ground braid beneath the jacket.
4 cm [1.5 in]
5. Insert the folded conductors into the crimp connector (use only
one connector) on the opposite end insert a stripped section of
a jumper wire to act as a ller. Crimp securely. Cut off excess
jumper wire. Next, pull slightly on the crimp to ensure that the
conductors are securely held.
JUMPER
WIRE
1.5 cm [0.6 in]
JACKET
COPPER BRAID
INSULATION
CONDUCTORS
4. Strip 1.5 cm (0.6 in) of insulation from the ends of the paired
heating element conductors and fold these conductors back into
a hook shape 6 mm (0.25 in) long.
6 mm [0.25 in]
CRIMP
CONNECTOR
6. Slide one short shrink tube over the crimped heating cable
conductors, ensuring that the shrink tube provides at least
13 mm (0.5 in) of overlap over the insulation. Starting at the
center of the shrink tube, heat with heat gun until completely
shrunk. Before the shrink tube becomes completely shrunk,
use a pair of pliers to pinch the end closed.
7. Position the small shrink tube over entire splice area. The heat
shrink can be shortened, but make sure will overlap the splice
area by 2.5 cm (1 in). Starting at the center of the shrink
tube, heat with heat gun until completely shrunk. Before the
shrink tube becomes completely shrunk, use a pair of pliers
to pinch the end closed. The heat shrink must extend 2 cm
(0.75 in) past the end of the splice.
2.5 cm [1 in]
SHORT
HEAT SHRINK
TUBE
SMALL
HEAT SHRINK
TUBE
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat www.easyheat.com 14137-000 Rev 3
6
TESTING
1. Test the resistance between the primary conductors of the cold lead with an ohmmeter. Record the resistance in the Repair and Test Record.
2. Test the insulation resistance of the cable between the primary conductor and the ground braid with a 500 VDC megger. The resistance
should be greater than 50 Megohms. Record the resistance in the Repair and Test Record. The insulation resistance should be
measured at least 30 min after finishing repair, when the splice is at ambient temperature. Measuring the insulation resistance
on a hot splice can lead to incorrect readings.
Dual Heating Cable
Insulation Resistance Test:
megohmmeter at 500 V (minimum) and measure the resistance.
Resistance Test:
Connect an ohmmeter between the two conductors of the cable. Measure the resistance.
Connect a megohmmeter between the copper grounding braid and the two conductors connected together. Set the
Single Heating Cable
Insulation Resistance Test:
Ensure the other lead is isolated and the heating element is not in contact with the ground braid. Set the megohmmeter at 500 V (minimum)
and measure the resistance.
Resistance Test:
resistance test is appropriate for the marked wattage and voltage.
Connect an ohmmeter between the inner conductors of the two leads of the mat. Measure the resistance. Be certain that the
Connect a megohmmeter between the copper grounding braind and the inner conductor on one lead of a mat.
REPAIR AND TEST RECORD
Repair Address_________________________________________________________ Repair Date____________________
Repair Location (driveway)_____(sidewalk)_____(stairs)_____(others)_________________________________________
Cause of Damage _______________________________________________ Repair Completed by____________________
Original Cable Length________________ Cable/Mat Model Number_____________________________________________
Heater Resistance (Ω)_______________ Ground Continuity (Yes) Insulation Resistance (MΩ)______________________
Notice: RepaiRiNg a damaged cable will void the oRigiNal heatiNg cable waRRaNty.
US T. (800) 537-4732
CAN T. (800) 794-3766
©2013 EasyHeat EasyHeat, Inc. is a wholly owned subsidiary of EGS Electrical Group LLC. 14137-000 Rev 3
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