nvent RAYCHEM E-100-LR-A, RAYCHEM E-100-LR-E Installation Instructions Manual

E-100-LR-A  E-100-LR-E

Light Replacement and Retrofit Kit for
High-Profile End Seal Installation Instructions

APPROVALS

Hazardous Locations

sira

(1)

Except VPL

* For system Temperature Code, see heating cable or design documentation

KIT CONTENTS

Item Qty Description

A 1 Light assembly
B 1 Core sealer (for BTV, QTVR, XTV, and KTV)
C 2 Insulated butt splices (red)
D 2 Insulated parallel crimps (blue)
E 1 Cable tie

Class I, Div. 2, Groups A, B, C, D
Class II, Div. 1 and 2, Groups E, F, G
Class III

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DESCRIPTION

The nVent RAYCHEM E-100-LR-A and E-100-LR-E light kit is used
to replace the light on an E-100-L high-profile lighted end seal or
to retrofit a light to an existing E-100 high-profile end seal.

This kit may be installed at temperatures as low as –40°F
(–40°C). For easier installation store above freezing until just
before installation.

– E-100-LR-E kit is used for E-100-E and E-100-L-E kits
– E-100-LR-A kit is used for E-100-A and E-100-L-A kits

For technical support call nVent at (800)545-6258.

TOOLS REQUIRED

• Wire cutters • Rags or dry towel

• Utility knife • Wire strippers

• Marker • Needle nose pliers

• Panduit CT-100 crimp tool or equivalent

A

B

C

E

D

This component is an electrical device that

WARNING:

CAUTION:

must be installed correctly to ensure proper
operation and to prevent shock or fire. Read
these important warnings and carefully follow
all of the installation instructions.

• To minimize the danger of fire from
sustained electrical arcing if the heating
cable is damaged or improperly installed,
and to comply with the requirements of
nVent, agency certifications, and the National
Electrical Code, ground-fault equipment
protection must be used. Arcing may not be
stopped by conventional circuit breakers.

• Component approvals and performance are
based on the use of nVent-specified parts
only. Do not use substitute parts or vinyl
electrical tape.

HEATING CABLE TYPES

Braid

Inner jacket

Conductive core

Bus wire

BTV-CR, BTV-CT, QTVR-CT

• The black heating cable core and fibers are
conductive and can short. They must be
properly insulated and kept dry.

• Damaged bus wires can overheat or short.
Do not break bus wire strands when scoring
the jacket or core.

• Keep components and heating cable ends
dry before and during installation.

• Bus wires will short if they contact each
other. Keep bus wires separated.

• Use only fire-resistant insulation materials,
such as fiberglass wrap or flame-retardant
foam.

• Leave these installation instructions with

theuser for future use.

Outer
jacket

Bus wire

XTV-CT, KTV-CT

Inner jacket

Conductive fiber

Spacer

Outer jacket

Braid

VPL-CT

Bus wire connection

Clear jacket

Insulated bus wire

Health Hazard: Prolonged or repeated contact
with the sealant in the core sealer may
cause skin irritation. Wash hands thoroughly.
Overheating or burning the sealant will
produce fumes that may cause polymer fume
fever. Avoid contamination of cigarettes or

tobacco. Consult MSDS VEN 0058 for further

information.

CHEMTREC 24-hour emergency telephone:
[phone].

Non-emergency health and safety information:
[phone].

Outer
jacket

Braid

Inner jacket

Heating element

Light

Replacement

Go to Step A

Light

Retrofit

Go to Step 1

(page 6)

2 3

CAUTION: Health Hazard.

Wash hands if you contact
sealant. Consult MSDS
VEN 0058.

• Remove and discard boot.

• Using a dry towel, clean
sealant from end of heating
cable.

1

BEGIN HERE FOR LIGHT RETROFIT.

WARNING: Shock Hazard.

Electrical conductors will be
exposed. Re-entry should
only be performed by
qualified personnel. Turn off
power and follow standard
electrical lockout
procedures before opening
end seal.

BTV, QTVR

XTV, KTV

VPL

• Turn off power.

• Clip cable tie and
remove.

• Unscrew cap from
end seal stand.

• Remove cap from
yellow leash.

Go to Step 4A

Go to Step 4A

Go to Step 4B

2 | nVent.com

4A

BTV, QTVR

4B

VPL

• Ensure 1 1/4 in (32 mm) of

heating cable is exposed
above end seal strain relief.

• Mark heating cable jacket.

• Lightly score jacket
around and up as
shown.

XTV, KTV

1 1/4 in

(32 mm)

5/8 in

(16 mm)

Do not cut
bus wires.

Strain
relief

• Ensure 1 1/8 in (28 mm) of

heating cable is exposed
above end seal strain relief.
The conductor should
remain staggered.

• Lightly score jacket
around and up as

Do not cut
bus wires.

shown.

• Peel off jacket.

• Unwind heating element, cut
and remove as shown.

1 1/8 in

(28 mm)

1/2 in

(13 mm)

Strain
relief

1/4 in

(6 mm)

• Peel off jacket.

• Determine heating cable
type and continue as
shown.

BTV, QTVR

XTV, KTV

Go to Step 5a

Go to Step 5b

• Lightly score clear jacket
around and up as shown.

• Peel off jacket.

• Remove insulation from
ends of bus wires.

Note: Core sealer is not
used on VPL.
Discard core sealer.

1/4 in

(6 mm)

1/2 in

(13 mm)

1/2 in

(13 mm)

Skip Step 5 and go to Step 6

nVent.com | 3

5A

BTV, QTVR

5B

XTV, KTV

• Notch core.

• Peel bus wire from core.

• Score core between bus
wires at jacket.

Do not cut
bus wires.

• Bend and snap core.

• Peel core from bus wires.

• Remove any remaining
core material from bus
wires.

CAUTION: Health Hazard.

Wash hands if you contact
sealant. Consult MSDS
VEN 0058.

• Cut and remove
all fiber strands.

Do not cut
bus wires.

• Score and remove center
spacer.

• Remove any remaining
core material from bus
wires.

CAUTION: Health Hazard.

Wash hands if you
contact sealant. Consult
MSDS VEN 0058.

• If needed, retwist and
straighten bus wires.

Make sure the

bus wires do not

kink, bunch, or

crossover.

• Insert bus
wires into
guide tubes
as shown.

• Slide core
sealer onto
heating cable.

• If needed,
retwist and
straighten bus
wires.

• Insert bus wires

Make sure the

bus wires do not

kink, bunch, or

crossover.

into guide tubes
as shown.

• Slide core sealer
onto heating cable.

• Remove the guide tubes
and dispose of them in a
plastic bag.

4 | nVent.com

Go to Step 6

• Remove the guide tubes
and dispose of them in a
plastic bag.

Go to Step 6

6

• Install new light assembly into leash.

• Crimp bus wires to lead wires.

• Place blue crimps onto bus wires.

Insulated
parallel
crimps

7

• Push excess wire inside light. • Hand tighten light onto end seal stand.

• Insert cable tie through slots on stand and light then tighten.

Be sure wires

are not caught

in threads.

8

• Leave these instructions with the end user for future
reference.

Trim

Weather seal

Go to Page 8

nVent.com | 5

A

BEGIN HERE FOR LIGHT REPLACEMENT

WARNING: Shock hazard. Electrical conductors will

beexposed. Re-entry should only be performed by

qualified personnel. Turn off power and follow
standard electrical lockout procedures before

openingend seal.

Note: The existing light shown in the instructions may look
different from the existing light in your installation.

B

• Cut existing wires approximately 2 in (50 mm) above top

of crimps or core sealer.

• Remove old light from yellow leash.

On existing light:

• Cut cable tie (if present).

• Unscrew light.

• Pull excess wire from inside light.

C

• Install new light
into yellow leash.

2 in

(50 mm)

Leash

D

• Use 20 AWG wire stripper to remove insulation from each

of the four wire ends.

3/8 in

(9 mm)

3/8 in

(9 mm)

E

• Use Panduit CT-100
crimp tool and red
insulated butt splices to
crimp new wires to old
wires.

6 | nVent.com

F

• Push excess wire inside light. • Hand tighten light onto end seal stand.

• Insert cable tie through slots on stand and light then tighten.

Be sure wires

are not caught

in threads.

G

• Leave these instructions with the end user for future
reference.

Trim

Weather seal

Go to Page 8

nVent.com | 7

Troubleshooting Guide

Problem Troubleshooting steps
Light is dim or off.

1. Check that light voltage rating matches supply voltage for heat-tracing circuit. Supply voltage lower or higher than light
rating will cause malfunctions.

2. Check that heat-tracing circuit is energized. Although the circuit breaker is on, control devices such as thermostats

may switch heating cable off.

3. Following electrical safety procedures, disconnect supply voltage, unscrew light from end seal base and check that

crimp connections to heating cable bus wires are tight and not crossed or shorted. Loose connections or shorts will
cause malfunctions.

4. With circuit off, attach volt meter leads to crimps. Energize circuit and measure voltage at light. Use the following table

to determine whether the voltage measured is within the acceptable range of 100-305 Vac.

• If voltage at light is in acceptable range and connections are good, the light may be defective or damaged.

Replacelight.

• If there is no voltage at the light, there may be breaks in the heating cable between the power connection and

theendseal. Check for splice or tee connections that may be left open.

• If voltage at light is above specified limits, the light may be off. Voltages above specified range can damage light.
Replace light with correct version for line supply voltage or adjust supply voltage accordingly.

• If voltage at light is present but below specified limits, the light may be dim or off. The following table lists typical
causes for low voltages and possible solutions.

Cause Solution

Supply voltage at start of circuit is low (light is designed
to work with supply voltages within 10% of nominal).

Heating cable length is too long (light is designed to
work with published maximum circuit lengths).

Heating cable is started under very cold conditions
(heating-cable voltage drop is very high for first minutes
of very cold start-up).

Heating cable controller is reducing voltage (light may not
work with controllers that phase fire to reduce line voltage).

Increase power wire gauge size to reduce voltage drop
between panel and heating cable power connection.

Split heating cable into multiple circuits. Shorten length
of heating cable.

Wait for heating cable to warm up. Voltage at light

willincrease.

Turn off phase firing function in heating cable controller.

Problem Troubleshooting steps

Cap cannot be
tightened completely.

North America

Tel [phone]
Fax [phone]

[e-mail]

1. Check that heating cable is installed and stripped correctly. The top of the insulated parallel crimps should be

23/8 in (60 mm), or less, above the top of the plastic strain relief in the stand.

2. Check that core sealer is positioned properly. The end of the core sealer must be flush against the plastic strain relief

in the stand.

3. Check that the threads on the light and stand are clean. The connection wires between the heating cable and the light

should not be caught in stand threads.

Europe, Middle East, Africa

Tel [phone]
Fax [phone]

[e-mail]

Asia Pacific

Tel [phone]
Fax [phone]

[e-mail]

Latin America

Tel [phone]
Fax [phone]

[e-mail]

©2018 nVent. Al l nVent marks and logos a re owned or license d by nVent Service s GmbH or its affi liates. All other tr ademarks are the p roperty of the ir respective own ers.
nVent reser ves the right to chang e specificat ions without noti ce.

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