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