Nelson Heat Trace ALT-BC, ALT-BCL Installation Guide

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

DESCRIPTION

The ALT-BC Standard Power Connection Kit is
constructed of cast aluminum for use with all versions
of Nelson Heat Tracing Systems’ LT, CLT, HLT and
NC heater cables. Compatible for use with any vendor’s
heater cables smaller than 11mm (0.44”) diameter.

Power Termination

Junction Box

Conduit Plug

*Ground Wire

(for grounding of braid)

KIT CONTENTS

1 Junction Box 1 Power Termination
1 Label 1 Washer
1 Terminal Block 1 Ground Screw
1 Conduit Plug 1 End Seal
1 Sealing Grommet 1 Tube of Silicone
1 Stand-off 2 Pipe Clamps

Silicone

Box Cover Gasket

INSTRUCTIONS

Box Cover

Washer; metal
**Sealing Grommet

*Conduit & Drain

*Heater Cable; braided cable optional

(see warnings)

End Seal

Stand-off

Pipe Clamp

**Sealing Grommet

J-Grommet - Overjacket Products
B-Grommet - Base Products
U-Grommet - Double Entry or non-standard construction

(For dual connections 1 additional power termination
and end will be included in kit.)

*ITEMS NOT INCLUDED IN KIT

Note: This detail shows Braided “CB” Product only. For Overjacket “J” or “JT” Products, see
diagram on sheet 8.

!

WARNINGS:

• Article 427 of the National Electric Code requires that all heaters shall have metal coverings and

be provided with branch circuit ground-fault protection.

• If nuisance tripping of ground fault breakers occurs due to condensation in the junction box,
electrical connections should be moisture proofed by use of a coating or sealant.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

September 2005

GA-1865 Rev. 6

Sheet 1 of 8

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

INSTRUCTIONS

STAND-OFF POSITIONING

Section View A A

(recommend installing at the

4 or 8 o'clock positions.)

!

WARNING:

Do not place pipe clamps

8 o'clock

4 o'clock

254mm (10")

A

over the heater cable.

Pipe Clamps

A

Fiberglass Tape

not included in kit

Stand-off

Fiberglass Tape

not included in kit

Stand-off

Sealing Grommet

 Mark pipe where stand-off will be mounted. See drawing above.
 Push heater cable through bottom opening of stand-off.
 Place stand-off on pipe and fasten with pipe clamps included.
 Slide the sealing grommet over the heater cable and position inside stand-off opening:

For Braided “CB” Products only:
See “Sealing Grommet Installation for Braided “CB” Products” on sheet 3.

 Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.
 Prepare heater cable for power termination:

for Braided “CB” Products, see sheet 3.
for Overjacket “J” or “JT” Products, see sheet 4.

 Terminate heater cable, see sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1865 Rev. 6

Sheet 2 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

SEALING GROMMET INSTALLATION FOR BRAIDED “CB” PRODUCTS

13mm (.5")

 Slide braid back, allowing at least 13mm (.5”) of

heater cable exposed.

 Cut and remove the exposed heater cable.

BRAIDED “CB” PRODUCTS

 Slide braid back over heater cable and twist excess

braid into a pigtail.

 Slide the sealing grommet over the heater cable and

position inside stand-off opening.

 Continue with step 5 on sheet 2.

INSTRUCTIONS

127mm (.5")

 Bend heater cable and work it through the braid

opening.

 Secure heater cable braid with fiberglass tape,

allowing 127mm (5”) of cable for stripping.

114mm (4.5")

 Slide braid back towards the fiberglass tape creating

a bulge.

 At the bulge, separate the braid to make an opening.

 Pull the braid tigh t.
 Proceed to “LT, CLT & HLT Products” on sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

September 2005

GA-1865 Rev. 6

Sheet 3 of 8

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

OVERJACKET PRODUCTS

127mm (5")

!

WARNING:

DO NOT CUT BRAID

 Lightly cut around heater overjacket 127mm (5")

from the end. Bend cable to break overjacket.

 Lightly cut overjacket up the center between first

cut mark and the cable end. Bend cable to break
overjacket.

 At the bulge, separate the braid to make an opening.

INSTRUCTIONS

 Remove overjacket from heater cable.

 Move braid back toward the overjacket, creating

a bulge.

 While bending the heater cable, work it through the

braid opening.

114mm (4.5")

 Pull the braid tight.
 Proceed to “LT, CLT & HLT Products” on sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1865 Rev. 6

Sheet 4 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

FOR ALL NELSON LT, CLT & HLT PRODUCTS

(See sheet 6 for an alternate stripping method for HLT products.)

102mm (4")

 Lightly cut around cable outer jacket 102mm (4")

from the end. Bend cable to break outer jacket.

 Lightly cut the outer jacket up the center between

the first cut mark & the cable end. Bend cable to
break outer jacket.

 Starting at the end, pull each bus wire away from

the core material.

 Remove exposed core material.

INSTRUCTIONS

 Remove the jacket from the heater cable.

!

DO NOT CUT BUS WIRES

 Cut 6mm (0.25") off the end of each bus wire.
 Proceed to “Power Termination” on sheet 7.

 Shave the core material from the outside of

each bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1865 Rev. 6

Sheet 5 of 8

September 2005

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

HLT PRODUCTS ALTERNATE STRIPPING METHOD

102mm (4")

 Lightly cut around cable outer jacket 102mm (4")

from the end. Bend cable to break outer jacket.

 Lightly cut the outer jacket up the center between

the first cut mark & the cable end. Bend cable to
break outer jacket.

 Starting at the end, in the same plane as the cable,

pull each bus wire away from the core material.

INSTRUCTIONS

 Remove the exposed core material.

 Remove the jacket from the heater cable.

 Remove the remaining core material off the outside

 Make a cut inside each bus wire.

of each bus wire.

 Cut 6mm (0.25") off the end of each bus wire.
 Proceed to “Power Termination” on sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1865 Rev. 6

Sheet 6 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

POWER TERMINATION

!

WARNING:

• Bus wires must not touch or cross while

inserting into power termination.

• Only power terminations / end seals

specifically approved for the vendors style
and type of heater cable must be used.

apply silicone here

 Insert bus wires into power termination.

 Squeeze power termination opening and fill with

silicone.

END SEAL

Fiberglass Tape

not included in kit

 Push power termination to overlap jacket.
 The silicone will set up in about 30 minutes with a

complete cure after 24 hours.

 Proceed to “Power Termination” on sheet 8.

apply silicone here

INSTRUCTIONS

13mm (.5")

 Braided “CB” Products only:

Cut braid back 25mm (1") & tape in place with

fiberglass tape.

Overjacket “J” or “JT” Products only:

Remove 13mm (0.5") of overjacket exposing the

braid, then remove the 13mm (0.5”) of exposed
braid.

 Make a 10mm (0.4") cut at the end of the heater

cable.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

 Squeeze end seal and fill with silicone.
 Push end seal over the heater cable.

Overjacket “J” or “JT” Products only:
The end seal should overlap the overjacket.

 The silicone will set up in about 30 minutes with a

complete cure after 24 hours.

 Proceed to “Power Connection” on sheet 8

!

WARNING:

• Do not megger or hi-pot until

silicone is completely secured.

• Braid must be kept away from

bus wires or shorting will occur.

GA-1865 Rev. 6

September 2005

Sheet 7 of 8

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BC STANDARD POWER CONNECTION KIT

POWER CONNECTION

Terminal Block

Ground Wire

*Ground Wire

Braid

Power Termination

TERMINAL BLOCK CONNECTION

Ground Wire
Power Leads

INSTRUCTIONS

Braid
Heater Cable

*Conduit & Drain; not included in kit

(must be positioned lower than the junction box)

Note: This detail shows Overjacket “J” or “JT” Products. For Braided “CB” Products, see diagram on
sheet 1.

 Slide washer over heater cable and position at the sealing grommet.

 Secure junction box onto stand-off until tightly fitted. DO NOT OVER TIGHTEN.
 Connect the power wiring and heater cable to terminal block.

 Connect ground wire to terminal block inside junction box using the ground screw. See diagram on sheet 1.
 Connect ground wire and braid to terminal block. See diagram above.

 For Overjacket J or JT Products only:

Apply silicone at point braid leaves the overjacket.

 Push all wires, cable and terminal block inside junction box.
 Install box cover gasket and box cover onto junction box.

 Apply label to the smooth side of junction; fill-in the Voltage, Catalog No. & Wattage blocks on the label with the

actual field installed data.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1865 Rev. 6

Sheet 8 of 8
September 2005

www.nelsonheaters.com.

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT

DESCRIPTION

The ALT-BCL Standard Power Connection Kit is
constructed of cast aluminum for use with Nelson Heat Tracing
Systems’LLT heater cables.

Power T erm ina tion

Label

Junction Box

Conduit Plug

KIT CONTENTS

1 Junction Box 1 Power Termination
1 Label 1 Washer
1 Terminal Block 1 Ground Screw
1 Conduit Plug 1 End Seal
1 Sealing Grommet 2 Tubes of Silicone
1 Stand-off 2 Pipe Clamps

Silicone

*Ground Wire
(for grounding of braid)

INSTRUCTIONS

Box Cover Gasket

Washer, metal

Sealing Grommet

*Conduit & Dr ain

End Seal

*Heater Cab le

Standoff

Pipe Clamps

*TH E SE IT E M S N O T IN C L U D E D IN K IT .

!

WARNINGS:

• Article 427 of the National Electric Code requires that all heaters shall have metal coverings and

be provided with branch circuit ground-fault protection.

• If nuisance tripping of ground fault breakers occurs due to condensation in the junction box,
electrical connections should be moisture proofed by use of a coating or sealant.

Box Cover

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2179 Rev. 1

Sheet 1 of 6

September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT INSTRUCTIONS

STAND-OFF POSITIONING

Section View A A

(recommend installing at the

4 or 8 o'clock positions.)

!

WARNING:

Do not place pipe clamps

8 o'clock

4 o'clock

254mm (10")

A

over the heater cable.

Pipe Clamps

A

Fiberglass Tape

not included in kit

Stand-off

Fiberglass Tape

not included in kit

Stand-off

Sealing Grommet

 Mark pipe where stand-off will be mounted. See drawing above.
 Push heater cable through bottom opening of stand-off.
 Place stand-off on pipe and fasten with pipe clamps included.
 Slide the sealing grommet over the heater cable and position inside stand-off opening:

 Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.
 Prepare heater cable for power termination:

See sheet 3.

 Terminate heater cable, see sheet 5.

.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2179 Rev. 1

Sheet 2 of 6

September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT INSTRUCTIONS

OVERJACKET STRIPPING PROCEDURES

1

0

8

m

m

(

4

.

!

WARNING:

DO NOT CUT BRAID

2

5

"

)

 Lightly cut around heater overjacket 127mm (5")

from the end. Bend cable to break the overjacket.

 Lightly cut overjacket up the center between first

cut mark and the cable end. Bend cable to break

outer jacket will be removed in a subsuquent
operation do not puncture it with the awl.

102mm(4" )

 After the braid has been unraveled so that it looks

similar to the illustration above pull it tight and twist
the loose wires together.

 Proceed to “Outer Jacket Stripping Procedures”,

sheet 4.

 Remove overjacket from heater cable.

 Using an awl or other sharp pointed device, unravel

the braid from the cable. Even though most of the

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2179 Rev. 1

Sheet 3 of 6

September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT INSTRUCTIONS

OUTER JACKET STRIPPING PROCEDURES

 Lightly cut around heater outer jacket 102mm (4")

from the end. Bend cable to break outer jacket.

 Lightly cut the outer jacket up the center between

the first cut mark & the cable end. Bend cable to
break outer jacket.

 Starting at the end, pull each bus wire away

from the core material. Do not disturb the “lay” of
the wire stranding. Failure to comply will prevent
installation of the power termination boot.

 Remove exposed core material.

 Remove jacket from the heater cable.

 Proceed to “Power Termination Procedures”,

sheet 5.

!

DO NOT CUT BUS WIRES

 Shave core material from the outside of

each bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2179 Rev. 1

Sheet 4 of 6

September 2005

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT

POWER TERMINATION

!

WARNING:

• Bus wires must not touch or cross while

inserting into power termination.

• Only power terminations / end seals

specifically approved for the vendor’s style and
type of heater cable must be used.

apply silicone here

 Before installing the boot, slightly cock the end of

each wire away from the other and apply a small
amount of silicone to the open end of the boot.

 Insert bus wires into power termination (boot).

END SEAL

 Squeeze power termination opening and fill with

silicone.

 Push power termination to overlap jacket.
 The silicone will set up in about 30 minutes with a

complete cure after 24 hours.

 Proceed to “Power Connection” on sheet 8.

INSTRUCTIONS

13mm (.5")

apply silicone here

 Squeeze end seal and fill with silicone.
 Push end seal over the heater cable.

 Remove 13mm (0.5") of overjacket exposing the

braid, then remove the 13mm (0.5”) of exposed
braid.

 Make a 5mm (0.2") cut at the end of the heater

cable, as shown above.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

The end seal should overlap the overjacket.

 The silicone will set up in about 30 minutes with a

complete cure after 24 hours.

 Proceed to “Power Connection” on sheet 8

!

WARNING:

• Do not megger or hi-pot until

silicone is completely secured.

• Braid must be kept away from

bus wires or shorting will occur.

GA-2179 Rev. 1

September 2005

Sheet 5 of 6

NELSON™ HEAT TRACING SYSTEMS INSTALLATION

ALT-BCL STANDARD POWER CONNECTION KIT

POWER CONNECTION

* Ground W ire

Terminal Block

Braid

Ground W ire

Pow e r T erm ina t ion

TERM INA L BLOCK CONNECTION

Ground Screw in enclosure

Ground W ire
Pow er Lea ds

INSTRUCTIONS

* Ground W ire

Braid
Heater Cable

* Conduit and Dra in; not included

(should be positioned lower than t he junct ion box)

 Slide washer over heater cable and position at the sealing grommet.

 Secure junction box onto stand-off until tightly fitted. DO NOT OVER TIGHTEN.
 Connect the power wiring and heater cable to terminal block.

 Connect ground wire to terminal block inside junction box using the ground screw. See diagram on sheet 1.
 Connect ground wire and braid to terminal block. See diagram above.
 Apply silicone at point braid leaves the overjacket.

 Push all wires, cable and terminal block inside junction box.
 Install box cover gasket and box cover onto junction box.

 Apply label to the smooth side of junction; fill-in the Voltage, Catalog No. & Wattage blocks on the label with the

actual field installed data.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at

www.nelsonheaters.com.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2179 Rev. 1

Sheet 6 of 6

September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

DESCRIPTION

The ALT-BS Splice Connection Kit is constructed of cast
aluminum for use all versions of Nelson Heat Tracing
Systems’ LT, CLT, HLT and NC heater cables. Compatible
for use with any vendor’s heater cables smaller than 11mm
(0.44”) diameter. Minimum installation temperature –40°C
(-40°F).

Power Terminations

Junction Box

Conduit Plug

Terminal Block

KIT CONTENTS

1 Junction Box 2 Power Terminations

Terminal Block 1 Washer

1

Conduit Plugs 1 Ground Screw

2

Sealing Grommet 1 Tube of Silicone

1

Stand-off 2 Pipe Clamps

1

Silicone

Box Cover Gasket

Box Cover

Washer; metal

Sealing Grommet

U-Grommet - Double Entry or non-standard construciton

Stand-off

Braid

*ITEMS NOT INCLUDED IN KIT

Pipe Clamps

Ground Screw

(for use with braided cables only)

Note: This detail shows external grounding of braid. For internal grounding of braid

(overjacket products), see sheet 8.

!

WARNINGS:

 Canadian Div. 2 Hazardous installations must use internal ground connection of braid. See sheet 8.
 Article 427 of the National Electric Code requires that all heaters shall have metal coverings and be

provided with branch circuit ground-fault protection.

 If nuisance tripping of ground fault breakers occurs due to condensation in junction box, electrical

connections should be moisture proofed by use of a coating or sealant.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 1 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

STAND-OFF POSITIONING

Section View A A

(recommend installing at the

4 or 8 o'clock positions.)

8 o'clock

4 o'clock

254mm (10")

A

!

WARNING:

Do not place pipe clamps
over the heater cable.

Pipe Clamps

INSTALLATION
INSTRUCTIONS

*Fiberglass Tape

*ITEMS NOT INCLUDED IN KIT

A

Stand-off

*Fiberglass Tape

Braid

Stand-off
Sealing Grommet

Power Termination

 Mark pipe where stand-off will be mounted.

 For External Braid Connection - CB Products only:

 Remove braid from heater cables, back to the point the cables leave the pipe. See Sheet 3.
 Proceed to step 3 below.

For Internal Braid Connection - CB, J or JT Products:
Proceed to step 3 below.

 Push heater cable through the bottom opening of stand-off.
 Place stand-off on pipe and fasten with pipe clamps.
 Slide the sealing grommet over heater cable and position inside stand-off opening.
 Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.
 Prepare heater cable for power termination:

for braided products, see sheet 3.
for overjacket products, see sheet 4.
for base products, see sheet 5.

 Terminate heater cable, see sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 2 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

BRAIDED PRODUCTS

see step 1 for the
correct dimensions.

 For External Braid Connection:

Move braid back 305mm (12”) to create a bulge.

For Internal Braid Connection:

Move braid back 127mm (5”) to create a bulge.

 At the bulge, separate the braid to make an

opening.

 While bending the heater cable, work it through

the braid opening.

 Pull the braid tight.
 Proceed to “LT, CLT & HLT Products”, sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 3 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

OVERJACKET PRODUCTS

127mm (5")

!

WARNING:

DO NOT CUT BRAID

 Lightly cut around heater overjacket 127mm (5")

from the end. Bend cable to break overjacket.

 Lightly cut overjacket up the center between first

cut mark and the cable end. Bend cable to break
overjacket.

 At the bulge, separate the braid to make an

opening.

 Remove overjacket from heater cable.

 Move braid back toward the overjacket,

creating a bulge.

 While bending the heater cable, work it through

the braid opening.

114mm (4.5")

 Pull the braid tight.

 Proceed to “LT, CLT & HLT Products”,

sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 4 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

FOR ALL NELSON LT, CLT & HLT PRODUCTS

(See sheet 6 for an alternate method of HLT products)

102mm (4")

INSTALLATION
INSTRUCTIONS

 Lightly cut around heater outer jacket 102mm

(4") from the end. Bend cable to break outer
jacket.

 Lightly cut the outer jacket up the center between

the first cut mark & the cable end. Bend cable to
break outer jacket.

 Remove the jacket from the heater cable.

!

WARNING:

DO NOT CUT BUS WIRES

 Starting at the end, pull each bus wire away from

the core.

 Remove exposed core material.

 Cut 6mm (0.25") off the end of each bus wire.
 Proceed to “Power Termination”, sheet 7.

 Shave the core material from the outside of each

bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 5 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

HLT PRODUCTS
ALTERNATE METHOD

102mm (4")

 Lightly cut around heater outer jacket 102mm

(4") from the end. Bend cable to break outer
jacket.

 Lightly cut the outer jacket up the center between

the first cut mark & the cable end. Bend cable to
break outer jacket.

 Starting at the end, in the same plane as the

cable, pull each bus wire away from the core.

 Remove the exposed core material.

 Remove the jacket from the heater cable.

 Make a cut inside each bus wire.

 Remove the remaining core material from the

outside of each bus wire.

 Cut 6mm (0.25") off the end of each bus wire.
 Proceed to “Power Termination”, sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 6 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

POWER TERMINATION

apply silicone here

!

WARNINGS:

 Bus wires must not touch or cross while

inserting into power termination.

 Only power terminations specifically

approved for the vendor’s style and type of
heater cable must be used.

 Insert bus wires into power termination.
 Squeeze power termination opening and fill with

silicone.

13mm (0.5")

 Push power termination to overlap jacket.
 Proceed to

“Power Termination”

, sheet 8.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 7 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

ALT-BS SPLICE CONNECTION KIT

POWER CONNECTION

Braid

Terminal Block

Power Terminations

Terminal Block Connection

INSTALLATION
INSTRUCTIONS

Braid

Heater Cable

Braid
Heater Cable

Note: This detail shows internal grounding of braid.

 Slide washer over heater cable and position at the sealing grommet.

 Secure junction box onto stand-off until tightly fitted. DO NOT OVER TIGHTEN.
 Connect bus and power wiring to the terminal block.

See diagram above.

 Ground connection:

For External Ground Connected Heaters:
Connect braid from both heater cables to the stand-off using the ground screw. See diagram on sheet 1.

For Internal Ground Connected Heaters:
Connect braid from both heater cables to the terminal block. See diagram above.

 For Overjacket J or JT Products only:

Apply silicone at point braid leaves the overjacket.

 Push all wires, both heater cables and terminal block inside junction box.

 Install box cover gasket and box cover onto junction box.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at www.nelsonheaters.com

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1866 Rev. 7

Sheet 8 of 8
January 2010

.

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

DESCRIPTION

The ALT-BY Tee Splice Connection Kit is constructed of
cast aluminum for use with all versions of Nelson Heat
Tracing Systems’ LT, CLT, HLT and NC heater cables.
Compatible for use with any vendor’s heater cables
smaller than 11mm (0.44”) diameter.

Power Terminations (2)

Junction Box

Terminal Block

Power Termination (1)

Sealing Grommet

J-Grommet - Overjacket Products
B-Grommet - Base Products

Connection Fitting

Flex Tubing

Washer (metal)

Conduit Plug

Washer (metal)

KIT CONTENTS

1 Junction Box 3 Power Terminations
1 Terminal Block 2 Washers
1 Conduit Plug 1 Ground Screw
2 Sealing Grommets 2 End Seals
1 Stand-off 1 Tube of Silicone
1 Flex Tubing 2 Pipe Clamps
1 Connection Fitting

Silicone

Box Cover Gasket

Box Cover

Sealing Grommet

U-Grommet - Double Entry, NC, or any other heater

Stand-off

*ITEMS NOT INCLUDED IN KIT

End Seal

*Heater Cable; braid optional

(see warnings below)

Ground Screw

(for braided heater cables only)

Pipe Clamps

Note: This detail shows external grounding of braid. For internal ground of braid (overjacket

products), see sheet 8.

!

WARNINGS:

• Canadian Div. 2 Hazardous installations must use internal ground connection of braid. See sheet 8.

• Article 427 of the National Electric Code requires that all heaters shall have metal coverings and be

provided with branch circuit ground-fault protection.

• If nuisance tripping of ground fault breakers occurs due to condensation in connection box, electrical

connection should be moisture proofed by use of a coating or sealant.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 1 of 8

September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

Section View A A

(recommend installing at the

4 or 8 o'clock positions.)

!

Do not place pipe clamps
over the heater cable.

INSTALLATION
INSTRUCTIONS

WARNING:

8 o'clock

4 o'clock

STAND-OFF POSITIONING

203mm (8")

305mm (12")

457mm (18")

*ITEMS NOT INCLUDED IN KIT

A

A

n Cut heater cables to lengths shown.

o External Braid Connection - CB Products

only:

• Remove braid from heater cables, back to the
point the cables leave the pipe. See Sheet 3.

• Proceed to step 3 below.

Internal Braid Connection - CB, J or JT

Products:

Proceed to step 3 below.

p Push the two 305mm (12”) heater cables through

the bottom opening of stand-off.

q Place stand-off on pipe and fasten with pipe

clamps.

r Slide the large opening sealing grommet over the

two heater cables and position inside stand-off
opening.

Pipe Tee

*Heater Cable

*Fiberglass Tape

Stand-off
Gasket

Sealing Grommet

Flex Tubing

Connection Fitting
Sealing Grommet

Washer; metal

s Apply silicone around heater cables on top of the

sealing grommet and fill any voids in sealing
grommet.

t Install flex tubing assembly over the 457mm (18”)

heater cable and tape at pipe tee with fiberglass
tape (not included in kit).

u Slide the gasket and small opening sealing

grommet over the single heater cable and
position inside connection fitting.

v Apply silicone around heater cable at top of the

sealing grommet and fill any voids in sealing
grommet.

w Prepare heater cables for power termination:

for braided products, see sheet 3.
for overjacket products, see sheet 4.
for base products, see sheet 5.

11

Terminate heater cables, see sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 2 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

BRAIDED PRODUCTS

p While bending the heater cable, work it through

the braid opening.

see step 1 for the
correct dimensions.

INSTALLATION
INSTRUCTIONS

n For External Braid Connection:

For heater cable going through the flex tubing ­move braid back 457mm (18”) to create a bulge.

For heater cables going through the stand-off -
move braid back 305mm (12”) to create a bulge.

For Internal Braid Connection:

Move braid back 127mm (5”) to create a bulge.

o At the bulge, separate the braid to make an

opening.

q Pull the braid tight.
r Proceed to “LT, CLT & HLT Products”, sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 3 of 8

September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

OVERJACKET PRODUCTS

!

WARNING:

DO NOT CUT BRAID

127mm (5")

n Lightly cut around heater overjacket 127mm

(5") from the end. Bend cable to break
overjacket.

o Lightly cut overjacket up the center between

first cut mark and the cable end. Bend cable to
break overjacket.

r At the bulge, separate the braid to make an

opening.

p Remove overjacket from heater cable.

q Move braid back toward the overjacket,

creating a bulge.

s While bending the heater cable, work it through

the braid opening.

114mm (4.5")

t Pull the braid tight.
u Proceed to “LT, CLT & HLT Products”, sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 4 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

FOR ALL NELSON LT, CLT & HLT PRODUCTS

(See sheet 6 for an alternate method of HLT products.)

102mm (4")

INSTALLATION
INSTRUCTIONS

n Lightly cut around heater outer jacket 102mm

(4") from the end. Bend cable to break outer
jacket.

o Lightly cut the outer jacket up the center

between the first cut mark & the cable end.
Bend cable to break outer jacket.

p Remove the jacket from the heater cable.

!

WARNING:

DO NOT CUT BUS WIRES.

r Starting at the end, pull each bus wire away

from the core material.

s Remove exposed core material.

t Cut 6mm (0.25") off the end of each bus wire.

u Proceed to “Power Termination”, sheet 7.

q Shave the core material from the outside of

each bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 5 of 8

September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

HLT PRODUCTS
ALTERNATE METHOD

102mm (4")

n Lightly cut around heater outer jacket 102mm

(4") from the end. Bend cable to break outer
jacket.

o Lightly cut the outer jacket up the center

between the first cut mark & the cable end.
Bend cable to break outer jacket.

r Starting at the end, in the same plane as the

cable, pull each bus wire away from the core
material.

p Remove the jacket from the heater cable.

q Make a cut inside each bus wire.

s Remove exposed core material.

t Remove the remaining core material off the

outside of each bus wire.

u Cut 6mm (0.25") off the end of each bus wire.

v Proceed to “Power Termination”, sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 6 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

INSTALLATION
INSTRUCTIONS

POWER TERMINATION

!

WARNINGS:

• Bus wires must not touch or cross while inserting

into power termination.

• Only power terminations / end seals specifically

approved for the vendor’s style and type of heater
cable must be used.

apply silicone here

n Insert bus wires into power termination.

o Squeeze power termination opening and fill

with silicone.

END SEAL

Fiberglass Tape

(not included in kit)

13mm (0.5")

p Push power termination to overlap jacket.
q At this point, if you’re installing the end seal,

see the “End Seal” section below. Otherwise,
proceed to “Power Connection”, sheet 8.

n Braided Products:

Cut braid back 25mm (1") & tape in place with

fiberglass tape; not included in kit.

Overjacket Products:

Remove 13mm (0.5") of overjacket exposing

the braid, then remove the 13mm (0.5”) of
exposed braid.

o Make a 10mm (0.4") cut at the end of the

heater cable.

apply silicone here

p Squeeze end seal and fill with silicone.

q Push end seal over the heater cable.

Overjacket Products:
The end seal should overlap the overjacket.

r The silicone will set up in about 30 minutes with

a complete cure after 24 hours.

s Proceed to “Power Connection”, sheet 8.

!

WARNINGS:

• Do not megger or hi-pot until silicone

is completely cured.

• Braid must be kept away from bus

wires or shorting will occur.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 7 of 8

September 2005

NELSON™ HEAT TRACING SYSTEMS

ALT-BY TEE SPLICE CONNECTION KIT

POWER CONNECTION

Braid

Terminal Block

Ground Wire

Power Terminations

TERMINAL BLOCK CONNECTIONS

INSTALLATION
INSTRUCTIONS

Braid

Heater Cable

Braid
Heater Cable

Note: This detail shows internal grounding of braid.

n Slide washer over the two heater cables and position at the sealing grommet.
o Secure junction box onto stand-off until tightly fitted. DO NOT OVER TIGHTEN.
p Secure the flex tubing assembly onto the junction box. (Braid if present, should be separated from the

heater cable in a pigtail as it leaves the sealing grommet entering the enclosure.)

q Ground Connection:

For External Ground Connected Heaters:

Connect ground braid from all three heater cables together using the ground screw. See diagram on sheet 1.

For Internal Ground Connected Heaters:
Connect ground braid and ground wire from all heater cables to the terminal block. See diagram above.

r For Overjacket J or JT Products only:

Apply Silicone at point braid leaves the overjacket.

s Push all wires, cables and the terminal block inside junction box.

t Place box cover and box cover gasket onto the junction box.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at

www.nelsonheaters.com.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1867 Rev. 5

Sheet 8 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

DESCRIPTION

The ALT-L Series End of Circuit Light Kit is constructed
of aluminum. For use with all versions of LT, CLT, HLT
and NC heater cables. Compatible for use with any
vendor’s heater cables smaller than 11mm (.44”)
diameter.

Voltage Kit Cat. #

120V ALT-L120
208V ALT-L208
240V ALT-L240
277V ALT-L277

Power Termination

Conduit Locknut

Light Assembly

Junction Box

KIT CONTENTS

1 Junction Box 1 Power Termination
1 Conduit Locknut 1 Box Adapter
1 Sealing Grommet 1 Gasket
1 Stand-off 1 Tube of Silicon e
1 Ground Screw 2 Pipe Clamps
1 Light Assembly 1 Piece of Shrink Tube
1 Caution Label

Box Cover

INSTRUCTIONS

Silicone

Gasket

Box Adapter

Sealing Grommet

J-Grommet - Overjacket Products
B-Grommet - Base Products
U-Grommet - NC or any other special

construction heaters

Stand-off

Pipe Clamp

Note: For internal grounding of braid see sheet 8.

Label

*Heater Cable

(see warning below)

*ITEMS NOT INCLUDED IN KIT

!

WARNING:

Article 427-22 of the National Electrical Code requires that all heaters shall have
metal coverings and be provided with branch circuit ground-fault protection.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

September 2005

Sheet 1 of 8

NELSON™ HEAT TRACING SYSTEMS

A

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

STAND-OFF POSITIONING

Section View A

(recommend installing at the

4 or 8 o'clock positions.)

8 o'clock

4 o'clock

254mm (10")

A

A

Fiberglass Tape

(not included in kit)

Stand-off

Fiberglass Tape

(not included in kit)

INSTRUCTIONS

!

WARNING:

Do not place pipe clamps
over the heater cable.

Pipe Clamps

Stand-off

Sealing Grommet
Box Adapter

Power Termination

n Mark pipe where stand-off will be mounted.

o Push heater cable through bottom opening of stand-off.
p Slide the sealing grommet over the heater cable and position inside stand-off opening:

for Braided “CB” Products:
See “Grommet Installation for Braided “CB” Products”, sheet 3.

for Overjacket “J” or “JT” Products

Proceed with step 4 below.

q Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.
r Slide the box adapter over the heater cable and tighten securely to stand-off.
s Prepare heater cable for power termination:

for Braided “CB” Products, see sheet 3.
for Overjacket “J” or “JT” Products, see sheet 4.

t Terminate heater cable, see sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

Sheet 2 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

SEALING GROMMET INSTALLATION FOR BRAIDED “CB” PRODUCTS

13mm (.5")

n Slide braid back, allowing at least 13mm (.5”) of

heater cable exposed.

o Cut and remove 13mm (.5”) of heater cable.

BRAIDED “CB” PRODUCTS

p Slide braid back over heater cable and twist

excess braid into a pigtail.

q Slide the sealing grommet over the heater cable

and position inside stand-off opening.

r Continue with step 4 on sheet 2.

INSTRUCTIONS

*Fiberglass Tape

(not included in kit)

127mm (5")

q While bending the heater cable, work it through

the braid opening.

114mm (4.5")

n Secure cable braid with fiberglass tape.
o Slide braid back 127mm (5”) to create a bulge.
p At the bulge, separate the braid to make an

opening.

r Pull the braid tight,
s Proceed to “LT, CLT & HLT Products”, sheet 5

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

September 2005

Sheet 3 of 8

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

OVERJACKET “J” or “JT” PRODUCTS

127mm (5")

!

WARNING:

DO NOT CUT BRAID

n Lightly cut around cable overjacket 127mm (5")

from the end. Bend cable to break the
overjacket.

o Lightly cut overjacket up the center between first

cut mark and the cable end. Bend cable to break
the overjacket.

r At the bulge, separate the braid to make an

opening.

INSTRUCTIONS

p Remove overjacket from heater cable.

q Move braid back toward the overjacket,

creating a bulge.

s While bending the heater cable, work it through

the braid opening.

114mm (4.5")

Pull the braid tight.

t
u Proceed to “LT, CLT & HLT Products”, sheet 5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

Sheet 4 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

FOR ALL NELSON LT, CLT & HLT PRODUCTS

(See sheet 6 for an alternate stripping method for HLT products.)

102mm (4")

n Lightly cut around cable outer jacket 102mm (4")

from the end. Bend cable to break outer jacket.

o Lightly cut the outer jacket up the center

between the first cut mark & the cable end. Bend
cable to break outer jacket.

r Starting at the end, pull each bus wire away from

the core material.

s Remove exposed core material.

INSTRUCTIONS

t Cut 6mm (0.25") off the end of each bus wire.

u Proceed to “Power Termination”, sheet 7.

p Remove the jacket from the heater cable.

!

WARNING:

q Shave the core material from the outside of each

bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

September 2005

Sheet 5 of 8

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

HLT PRODUCTS ALTERNATE STRIPPING METHOD

102mm (4")

n Lightly cut around cable outer jacket 102mm (4")

from the end. Bend cable to break outer jacket.

o Lightly cut the outer jacket up the center

between the first cut mark & the cable end. Bend
cable to break outer jacket.

r Starting at the end, in the same plane as the

cable, pull each bus wire away from the core
material.

INSTRUCTIONS

p Remove the jacket from the heater cable.

q Make a cut inside each bus wire.

s Remove the exposed core material.

t Remove the remaining core material off the

outside of each bus wire.

u Cut 6mm (0.25") off the end of each bus wire.

v Proceed to “Power Termination”, sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

Sheet 6 of 8
September 2005

NELSON™ HEAT TRACING SYSTEMS

g

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

POWER TERMINATION

!

WARNING:

Bus wires must not touch or cross
while insertin

apply silicone here

into power termination.

n Insert bus wires into power termination.
o Squeeze power termination opening and fill with

silicone.

p Push power termination to overlap jacket.

q The silicone will set up in about 30 minutes with

a complete cure after 24 hours.

r Proceed to “Electrical Connection”, sheet 8.

INSTRUCTIONS

13mm (.5")

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

September 2005

Sheet 7 of 8

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-L SERIES END OF CIRCUIT LIGHT KIT

ELECTRICAL CONNECTION

Power Termination

Heater Cable

Light Assembly

Ground Braid

Piece of Shrink Tube

Ground Screw

INSTRUCTIONS

Note: This detail shows internal grounding of braid.

n Place gasket onto the box adapter.

o Position junction box onto the box adapter and secure it with the conduit locknut.
p Place the two black compensating gaskets onto the light assembly base.

q Insert power wires into screw connection of light assembly.
r Slide piece of shrink tube over ground braid.

s Connect ground braid to the ground screw inside the junction box. See diagram above.
t Place the box cover onto the light assembly then install the clear trim washer and secure it with the ring nut.
u Secure the box cover onto the junction box.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-2027 Rev. 1

Sheet 8 of 8
September 2005

www.nelsonheaters.com.

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LP POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

DESCRIPTION

The ALT-LP Power Connection Kit without Enclosure is constructed
of cast aluminum for use with all versions of Nelson Heat Tracing
Systems’ LT, HLT & NC heater cables. Compatible for use with any
vendor’s heater cables smaller than 11mm (0.44”) diameter.

*Conduit & Drain

*Power Termination

*Junction Box

*Crimp Connector

*Conduit Plug

*Ground Wire

(for internal grounding of braid only)

Gasket
Box Adapter

KIT CONTENTS

1 Sealing Grommet 1 Gasket
1 Stand-off 1 Tube of Silicone
1 Ground Screw 1 Box Adapter
1 Conduit Locknut

Silicone

*Box Cover Gasket

*Box Cover

**Sealing Grommet

*End Seal

Stand-off

*Pipe Clamp

*Heater Cable; braid optional

(see warnings)

For Braided Heater Cables Only:

Connect braid using the ground screw.

**Sealing Grommets

J-Grommet - Overjacket Products
B-Grommet - Base Products
U-Grommet - Double Entry or non-standard construction

*ITEMS NOT INCLUDED IN KIT

Note: This detail shows external grounding of braid. For internal grounding of braid (overjacket

products), connect to ground screw inside of junction box.

!

WARNINGS:

• Canadian Div. 2 Hazardous installations must use internal ground connection of braid.

• Article 427 of the National Electric Code requires that all heaters shall have metal coverings and be

provided with branch circuit ground-fault protection.

• If nuisance tripping of ground fault breakers occurs due to condensation in junction box, electrical

connections should be moisture proofed by use of a coating or sealant.

PO BOX 726  TULSA, OK 74101  [phone]  FAX [phone]  www.nelsonheaters.com

GA-1890 Rev. 5

Sheet 1 of 2

September 2005

NELSON™ HEAT TRACING SYSTEMS

*

INSTALLATION

ALT-LP POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

STAND-OFF POSITIONING

Section View A A

(recommend installing at the

4 or 8 o'clock positions)

8 o'clock

4 o'clock

254mm (10")

A

!

WARNING:

Do not place pipe clamps
over the heater cable.

Pipe Clamps

*Fiberglass Tape

Stand-off

A

*Fiberglass Tape

Braid

*ITEMS NOT INCLUDED IN KIT.

n Mark pipe where stand-off will be mounted.

o For External Braid Connection - CB Products only:

• Remove braid from heater cables, back to the point the cables leave the pipe.

• Proceed to step 3 below.

For Internal Braid Connection - CB, J or JT Products:

• Proceed to step 3 below.

p Push heater cable through the bottom opening of stand-off.
q Place stand-off on pipe and fasten with pipe clamps.
r Slide the sealing grommet over heater cable and position inside stand-off opening.

Stand-off

Sealing Grommet
Box Adapter

Gasket

*Power Termination

s Apply silicone around the cable on top of the sealing grommet and fill any voids in sealing grommet.

t Prepare heater cable for power termination using an approved termination kit.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at

PO BOX 726  TULSA, OK 74101  [phone]  FAX [phone]  www.nelsonheaters.com

GA-1890 Rev. 5

Sheet 2 of 2
September 2005

www.nelsonheaters.com.

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

DESCRIPTION

The ALT-LPM Power Connection Kit without Enclosure is
constructed of cast aluminum for use with all versions of
Nelson Heat Tracing Systems’ LT, HLT & NC heater cables.
Compatible for use with any vendor’s heater cables smaller
than 11mm (0.44”) diameter. Minimum installation
temperature –40°C (-40°F).

*Conduit & Drain

Power Termination

*Junction Box

Terminal Block

*Conduit Plug

Gasket

KIT CONTENTS

1 Sealing Grommet 1 Power Termination

Stand-off 1 Terminal Block

1

End Seal 1 Gasket

1

Ground Screw 1 Tube of Silicone

1

Conduit Locknut 1 Box Adapter

1

Silicone

*Ground Wire

(for internal grounding of braid only)

*Box Cover Gasket

*Box Cover

Box Adapter

**Sealing Grommet

**Sealing Grommets

B-Grommet - Base Products
J-Grommet - Overjacket Products
U-Grommet - Double Entry or non-standard construction

(For dual connections 1 additional power termination
and end seal have been included in this kit.)

*ITEMS NOT INCLUDED IN KIT

End Seal

Stand-off

*Pipe Clamp

*Heater Cable; braid optional

(see warnings)

For Braided Heater Cables Only:

Connect braid using the ground screw.

Note: This detail shows external grounding of braid. For internal grounding of braid

!

WARNINGS:

 Canadian Div. 2 Hazardous installations must use internal ground connection of braid. See sheet 8.
 Article 427 of the National Electric Code requires that all heaters shall have metal coverings and be

provided with branch circuit ground-fault protection.

 If nuisance tripping of ground fault breakers occurs due to condensation in junction box, electrical

connections should be moisture proofed by use of a coating or sealant.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 1 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

*

A

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

(overjacket products), see sheet 8.

STAND-OFF POSITIONING

Section View A A

(recommend installing at the

4 or 8 o'clock positions)

8 o'clock

4 o'clock

254mm (10")

!

WARNING:

Do not place pipe clamps
over the heater cable.

Pipe Clamps

Stand-off

Sealing Grommet
Box Adapter

Gasket
*Power Termination

*Fiberglass Tape

*ITEMS NOT INCLUDED IN KIT

Stand-off

A

*Fiberglass Tape

Braid

1. Mark pipe where stand-off will be mounted.

2. For External Braid Connection - CB Products only:

 Remove braid from heater cables, back to the point the cables leave the pipe. See Sheet 3.
 Proceed to step 3 below.

For Internal Braid Connection - CB, J or JT Products:

 Proceed to step 3 below.

3. Push heater cable through the bottom opening of stand-off.

4. Place stand-off on pipe and fasten with pipe clamps.

5. Slide the sealing grommet over heater cable and position inside stand-off opening.

6. Apply silicone around the heater cable on top of the sealing grommet and fill any voids in sealing grommet.

7. Slide the box adapter over the heater cable and tighten securely to stand-off.

8. Prepare heater cable for power termination:

for braided products, see sheet 3.
for overjacket products, see sheet 4.
for base products, see sheet 5.

9. Terminate heater cable, see sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 2 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

BRAIDED PRODUCTS

(for external braid connection only)

see step 1 for the
correct dimensions.

1) For External Braid Connection:

Move braid back 305mm (12”) to create a
bulge.

2) For Internal Braid Connection:

Move braid back 127mm (5”) to create a
bulge.

3) At the bulge, separate the braid to make an

opening.

4) While bending the heater cable, work it

through the braid opening.

5) Pull the braid tight.

6) Proceed to “Base LT & HLT Products”, sheet

5.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 3 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

OVERJACKET PRODUCTS

!

WARNING:

DO NOT CUT BRAID

127mm (5")

1) Lightly cut around heater overjacket 127mm

(5") from the end. Bend cable to break
overjacket.

2) Lightly cut overjacket up the center between

first cut mark and the cable end. Bend cable
to break overjacket.

5) At the bulge, separate the braid to make an

opening.

3) Remove overjacket from heater cable.

4) Move braid back toward the overjacket,

creating a bulge.

6) While bending the heater cable, work it

through the braid opening.

7) Pull the braid tight.

8) Proceed to “LT, CLT & HLT Products”, sheet

5.

114mm (4.5")

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 4 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

FOR ALL NELSON LT, CLT & HLT PRODUCTS

(See sheet 6 for an alternate method of HLT products.)

102mm (4")

1) Lightly

2) Lightly cut the outer jacket up the center

3) Remove the jacket from the heater cable.

cut around heater outer jacket

102mm (4") from the end. Bend cable to
break outer jacket.

between the first cut mark & the cable end.
Bend cable to break outer jacket.

!

WARNING:

DO NOT CUT BUS WIRES.

5) Starting at the end, pull each bus wire away

from the core material.

6) Remove exposed core material.

7) Cut 6mm (0.25") off the end of each bus

wire.

8) Proceed to “Power Termination”, sheet 7.

4) Shave the core material from the outside of

each bus wire.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 5 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

HLT PRODUCTS
ALTERNATE METHOD

102mm (4")

1) Lightly

2) Lightly cut the outer jacket up the center

cut around heater outer jacket

102mm (4") from the end. Bend cable to
break outer jacket.

between the first cut mark & the cable end.
Bend cable to break outer jacket.

5) Starting at the end, in the same plane as the

cable, pull each bus wire away from the core
material.

3) Remove the jacket from the heater cable.

4) Make a cut inside each bus wire.

6) Remove exposed core material.

7) Remove the remaining core material off the

outside of each bus wire.

8) Cut 6mm (0.25") off the end of each bus

wire.

9) Proceed to “Power Termination”, sheet 7.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 6 of 8
January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

POWER TERMINATION

!

WARNINGS:

 Bus wires must not touch or cross while

inserting into power termination / end seal.

 Only power terminations / end seals

specifically approved for the vendor’s style
and type of heater cable must be used.

pply silicone here

1) Insert bus wires into power termination.

2) Squeeze power termination opening and fill

with silicone.

END SEAL

Fiberglass Tape

(not included in kit)

13mm (0.5")

3) Push power termination to overlap jacket.

4) At this point, if you’re installing the end seal,

see the “End Seal” section below. Otherwise,
proceed to “Power Connection”, sheet 8.

apply silicone here

3) Squeeze the end seal and fill with silicone.

4) Push end seal over the heater cable.

1) For Braided Products:

Cut braid back 25mm (1") & tape in place

with fiberglass tape.

For Overjacket Products:

Remove 13mm (0.5") of overjacket exposing

the braid, then remove the 13mm (0.5”) of

For Overjacket Products:
The end seal should overlap the overjacket.

5) The silicone will set up in about 30 minutes

with a complete cure after 24 hours.

6) Proceed to “Power Connection”, sheet 8.

exposed braid.

2) Make a 10mm (0.4”) cut at the end of the
heater cable.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

!

WARNINGS:

 Do not megger or hi-pot until silicone is

completely cured.

 Braid must be kept away from bus wi res

or shorting will occur.

GA-1893 Rev. 6

Sheet 7 of 8

January 2010

NELSON™ HEAT TRACING SYSTEMS

INSTALLATION

ALT-LPM POWER CONNECTION KIT WITHOUT ENCLOSURE INSTRUCTIONS

POWER CONNECTION

Terminal Block

Ground Wire

Braid

Power Termination

Box Adapter

TERMINAL BLOCK CONNECTION

Ground

Power Leads

*Conduit & Drain

(must be positioned lower than the junction box)

Braid
Heater Cable

Note: This detail shows internal grounding of braid.

1. Place gasket on box adapter.

2. Secure junction box onto box adapter until tightly fitted. DO NOT OVER TIGHTEN.

3. Connect the power wiring and heater cable to terminal block.

4. Ground Connection:

For External Ground Connected Heaters:

 Connect ground braid to stand-off using the ground screw. See diagram on sheet 1.

For Internal Ground Connected Heaters:

 Connect ground wire to terminal block inside junction box using the ground screw.

See diagram on sheet 1.

 Connect ground wire and braid to terminal block. See diagram above.

5. For Overjacket J or JT Products only:

Apply silicone at point braid leaves the overjacket.

6. Push all wires and heater cable inside junction box.

7. Install box cover gasket and box cover onto junction box.

Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's
website at www.nelsonheaters.com

.

P.O. BOX 726  TULSA, OK 74101  TEL [phone]  FAX [phone]  www.nelsonheaters.com

GA-1893 Rev. 6

Sheet 8 of 8
January 2010